Zenith Flooring was appointed to deliver a durable resin flooring system within the train maintenance shed at the South Wales Metro Depot in Taff’s Well.
The depot was subsequently opened during a visit from His Majesty The King, bringing national attention to a major transport facility in which Zenith had completed one of its largest flooring projects of the year.
Covering approximately 5,725m², the installation required extensive mechanical preparation, a heavy-duty slip-resistant epoxy system and clearly defined demarcation throughout the facility. The complete flooring programme was delivered within approximately three weeks.
The challenge
A train maintenance depot places considerable demands on its flooring. The completed surface needed to withstand regular pedestrian movement, maintenance activity, equipment and the operational conditions associated with a busy rail environment.
Safety and visibility were also central to the specification. The system therefore needed to provide:
- a durable finish across the 5,725m² floor area;
- reliable slip resistance in wet and dry conditions;
- clearly defined routes and operational zones;
- a robust finish around the inspection pits; and
- completion within a tightly controlled three-week programme.
Delivering the project required careful sequencing and close coordination between preparation, installation and line-marking teams.
Mechanical surface preparation
The existing concrete substrate was mechanically prepared using a combination of grinding and shot blasting.
This process removed surface contamination, laitance and weak material while creating the mechanical profile required for the resin system to bond securely.
Different preparation methods were used according to the condition and location of the substrate. Shot blasting allowed the main floor areas to be treated efficiently, while grinding provided greater control around edges, pits and detailed sections.
Thorough preparation was essential to the long-term performance of the completed system, particularly across such a large and operationally demanding environment.
Epoxy scratch coat
Following preparation, Zenith installed a scratch coat comprising high-build epoxy resin mixed with quartz sand.
This filled minor surface irregularities and created a strong, consistent base for the subsequent resin layers. It also helped establish the thickness and texture needed for a robust industrial flooring system.
Slip-resistant quartz finish
An additional broadcast of quartz aggregate was applied across the wet resin to build surface texture and increase slip resistance.
Once the aggregate had bonded, excess material was removed and the system was sealed with a high-build epoxy topcoat. This encapsulated the quartz while retaining the textured finish required for safe use.
Slip testing recorded results above 40 PTV in both wet and dry conditions. A Pendulum Test Value of 36 or higher is generally classified as presenting a low slip risk, providing the client with clear evidence of the completed floor’s performance.
Demarcation and pit-wall coatings
Clear floor markings were required to support safe movement and distinguish the different operational areas within the train shed.
Zenith applied two coats of epoxy resin to form the demarcation lines, creating durable markings capable of withstanding regular traffic and cleaning.
The walls of the inspection pits were also coated using a water-based epoxy system. This provided a clean, hard-wearing finish and completed the refurbishment across both the horizontal and vertical surfaces.
Delivered within three weeks
Completing a 5,725m² installation within approximately three weeks required detailed planning, coordinated labour and efficient movement between each stage of the programme.
Preparation, scratch-coat installation, aggregate broadcasting, sealing and demarcation were carefully sequenced so that work could progress continuously without compromising curing requirements or installation quality.
The completed train shed
The finished system provides the South Wales Metro Depot with a durable, clearly marked and slip-resistant floor suited to the demands of an active rail maintenance facility.
The project included:
- approximately 5,725m² of resin flooring;
- mechanical grinding and shot blasting;
- a high-build epoxy and quartz scratch coat;
- a broadcast quartz slip-resistant finish;
- wet and dry slip-test results above 40 PTV;
- epoxy demarcation throughout the shed; and
- water-based epoxy coatings to the inspection-pit walls.
The result is a practical, hard-wearing floor that supports safe navigation, ongoing maintenance activity and the long-term operation of the depot.
A major project for a nationally significant facility
The completed system provides the South Wales Metro Depot with a durable, clearly marked and slip-resistant floor suited to the demands of an active rail maintenance facility.
Seeing the depot formally opened during a visit from His Majesty The King was a proud moment for everyone involved in the wider development. For Zenith, it provided an opportunity to see the completed flooring in use within a major piece of Welsh transport infrastructure.
