Zenith Flooring was appointed to transform a working automotive workshop into a high-quality filming environment for National Geographic’s Car S.O.S.
The challenge
This environment required more than a standard workshop floor. The completed surface needed to:
- withstand regular use from vehicles, tools and restoration equipment;
- present a clean and uniform finish under high-output studio lighting;
- minimise imperfections that could become more visible on camera;
- provide a professional backdrop for wide-angle and close-up filming; and
- be installed and fully cured within a tightly controlled production programme.
The project was therefore not simply a floor refurbishment. It involved converting a functional workshop into a dual-purpose automotive and studio environment where durability and appearance were equally important.
Specifying the flooring system
Zenith specified a fast-curing decorative resin flake system capable of delivering a consistent, camera-ready finish without compromising the performance required in a working automotive space.
Products from the Resincoat Solutions RS Decoflake and RS Ultracoat ranges were selected to provide a uniform decorative appearance, strong wear resistance and a rapid return to service.
The flake finish also helped disguise minor visual variations across the floor, creating a more consistent surface when viewed beneath powerful studio lighting.
Mechanical preparation
Careful preparation was essential to the final appearance and long-term performance of the flooring system.
The existing concrete substrate was mechanically prepared to remove surface contamination, weak material and any elements that could affect adhesion. This also created the surface profile required for the resin system to bond effectively.
Once preparation was complete, a primer was applied to seal and stabilise the concrete before the decorative system was installed.
Decorative flake installation
A full flake broadcast was applied across the primed surface to achieve consistent colour, coverage and texture throughout the workshop.
Maintaining an even distribution was particularly important for this project, as variations that may be less noticeable in a conventional industrial setting could be exaggerated by studio cameras and lighting.
The system was then sealed with a fast-curing polyaspartic topcoat. This created a durable, hard-wearing finish while allowing the floor to return to service within the production schedule.
The completed studio floor
The installation delivered a significant improvement in both the performance and appearance of the space.
The worn concrete substrate was replaced with a seamless resin flake finish that provides a clean, consistent backdrop for filming. Its lightly textured appearance helps reduce the visibility of surface imperfections while reflecting studio light without creating an excessively glossy or distracting finish.
From wide studio shots to close-up vehicle work, the floor maintains a uniform appearance across the space while continuing to withstand the practical demands of automotive restoration.
The result is a high-specification workshop floor that meets the visual expectations of modern broadcast production without compromising its day-to-day functionality.
