PU Screed and Epoxy Resin Flooring at Grain Brewery, Norfolk

Shier Coatings installed a combined polyurethane screed and epoxy resin flooring system across approximately 90m² at Grain Brewery in Norfolk.

The flooring specification was divided into two systems according to the operating conditions within each part of the brewery.

Approximately 30m² at the front of the building received a hard-wearing epoxy resin system with non-slip aggregate. The rear 60m², containing the brewing tanks and regular washdown areas, received polyurethane screed at a nominal thickness of 6mm.

The Flooring Requirements

As a busy working brewery, the production facility required flooring capable of handling:

- Heavy brewing equipment and tanks

- Regular cleaning and washdown

- Moisture and liquid spillages

- Chemicals used during production and cleaning

- Heavy daily foot and operational traffic

- Increased slip risks in wet working areas

- Demanding food-and-beverage production conditions

Rather than installing the same flooring system throughout, two systems were selected to provide the correct performance for each area.

The Flooring Specification

The approximately 90m² project included:

- Preparation of the existing substrate

- DPM primer applied across the complete floor

- Approximately 30m² of non-slip epoxy resin flooring

- Non-slip aggregate added to the epoxy system

- Approximately 60m² of polyurethane screed

- Coarse aggregate broadcast into the primed PU areas

- Loose aggregate removed following curing

- PU screed installed at a nominal thickness of 6mm

DPM Primer Across the Complete Floor

The complete 90m² floor received a DPM primer before the separate epoxy and polyurethane flooring systems were installed.

This created a consistent primed substrate across both areas and prepared the floor for the different resin build-ups.

30m² Non-Slip Epoxy Resin Flooring

Approximately 30m² at the front of Grain Brewery received an epoxy resin flooring system.

A non-slip aggregate was added to the epoxy resin to create additional surface texture and improve grip underfoot.

This provided the front section of the brewery with a practical, hard-wearing finish suitable for regular traffic while remaining considerably easier to clean and maintain than untreated concrete.

The front-area build-up consisted of:

1. Prepared concrete substrate

2. DPM primer

3. Epoxy resin flooring

4. Non-slip aggregate finish

60m² of 6mm Polyurethane Screed

The rear section of Grain Brewery contains the production tanks and experiences the most demanding conditions, including regular washdowns, moisture, chemicals and heavy operational use.

Following application of the DPM primer, approximately 60m² of this area was fully blinded with coarse aggregate.

Once the primer had cured, loose and excess aggregate was removed. This left a heavily textured mechanical key for the polyurethane screed installed on top.

The PU screed was then applied throughout the tank and washdown areas at a nominal thickness of 6mm.

The rear-area build-up consisted of:

1. Prepared concrete substrate

2. DPM primer

3. Full coarse-aggregate broadcast

4. Loose aggregate removed after curing

5. Polyurethane screed installed at a nominal thickness of 6mm

Why PU Screed Was Used Around the Brewing Tanks

Polyurethane screed was selected for the rear production area because it provides a strong and hygienic surface suited to demanding brewery conditions.

Its benefits include:

- Resistance to regular cleaning and washdown

- Suitability for wet production areas

- Resistance to heavy equipment and daily traffic

- A seamless and hygienic finish

- Improved slip resistance

- Resistance to moisture and production chemicals

- Long-term durability under demanding use

The 6mm system provided increased protection in the areas exposed to the harshest operational conditions.

A Flooring System Matched to Each Area

Dividing the project into two flooring systems allowed Grain Brewery to receive the correct level of performance in each section.

The front area benefited from a practical non-slip epoxy resin finish, while the tank and washdown areas received a heavier-duty 6mm polyurethane screed.

This approach avoided overspecifying the less demanding front section while providing increased protection where regular washdowns, moisture, chemicals and heavy equipment created greater demands on the floor.