Following the successful completion and assessment of several trial areas, Zenith Flooring was appointed to deliver approximately 6,000m² of specialist resin flooring for one of Britain’s most recognisable automotive manufacturers.
The installation was completed over multiple phases, including weekend working and occasional night shifts, allowing the flooring programme to progress around the client’s manufacturing operations.
The challenge
The client was experiencing tyre squeal as vehicles moved through parts of the factory. Alongside reducing this unwanted noise, the new flooring needed to provide a high-quality gloss finish suited to a prestigious automotive manufacturing environment.
Some areas also required electrostatic dissipative performance, meaning the flooring specification had to vary according to the operational requirements of each zone.
The project therefore called for a system that could:
- reduce tyre squeal within the factory;
- provide a smooth, high-gloss appearance without relying on a separate surface coating;
- meet ESD requirements in designated areas;
- withstand regular vehicle and operational traffic; and
- be installed around an active manufacturing programme.
Trial areas and system selection
Before the wider project was awarded, Zenith installed several trial areas using different flooring options.
These trials allowed the client to assess the appearance and practical performance of each proposed system under real factory conditions. The selected solution demonstrated a significant reduction in tyre squeal and achieved the smooth, gloss finish required by the client.
Once the trial areas had been reviewed and approved, Zenith was instructed to proceed with the full 6,000m² installation.
Self-smoothing epoxy installation
Rather than applying a conventional resin coating, Zenith installed a self-smoothing epoxy flooring system.
The flowing material was applied across the prepared substrate to create a smooth and consistent finish with an inherent gloss. This met the client’s aesthetic requirements without the need for an additional decorative topcoat.
Two systems were used across the project:
- Arturo EP2490 ESD SL in areas requiring electrostatic dissipative performance; and
- Arturo EP2500 SL in areas where a standard self-smoothing epoxy finish was appropriate.
Using complementary systems allowed Zenith to maintain a consistent appearance throughout the factory while meeting the different technical requirements of individual production areas.
ESD flooring for sensitive areas
Electrostatic discharge can present a risk in environments containing sensitive electronic components, machinery or production processes.
In designated areas, the EP2490 ESD SL system was installed to help control static electricity and provide the required electrostatic dissipative performance.
Careful coordination was needed to ensure the transition between ESD and non-ESD areas remained visually consistent while each zone delivered the performance required by the client.
Phased working around production
The 6,000m² programme was completed over a series of planned visits rather than through a single continuous shutdown.
Zenith coordinated the preparation, installation and curing of each section around the factory’s operational schedule. Weekend working and occasional night shifts allowed areas to be completed and returned to service while minimising interference with production.
This phased approach required close communication with the client, particularly when controlling access, sequencing adjacent areas and protecting completed sections during the remaining works.
The completed factory floor
The finished installation provides the automotive facility with a smooth, seamless and high-gloss epoxy floor suited to its operational and visual requirements.
The selected systems reduced tyre squeal to a level approved through the client’s trial process, while the use of both standard and ESD self-smoothing epoxies delivered the correct performance in each area.
Completed across approximately 6,000m² and installed around a demanding production schedule, the project demonstrates Zenith Flooring’s ability to combine specialist technical requirements with the appearance expected within a prestigious automotive manufacturing environment.
