Industrial Epoxy Flooring at Newport Docks – 1,600m² Floor Refurbishment
Shier Coatings completed the preparation, repair and installation of a high-performance industrial epoxy flooring system across approximately 1,600m² at Newport Docks, South Wales.
This was a demanding industrial flooring project involving extremely hard concrete, more than 600 redundant floor bolts, extensive surface damage and difficult cold-weather conditions. The existing slab required several stages of mechanical preparation before the new epoxy system could be installed.
The Problem
The existing industrial concrete floor had been subjected to years of heavy use and contained more than 600 bolts and fixings left within the slab.
Once the bolts were removed, hundreds of holes and damaged areas required individual repair. The concrete was also exceptionally hard, making the surface preparation physically demanding and considerably slower than it would be on a standard concrete floor.
Cold conditions inside the building created further challenges. The floor temperature, air temperature, humidity and dew point had to be monitored throughout the installation to prevent condensation from affecting the primer or epoxy coating.
What We Did
Our work included:
- Removal of more than 600 bolts and redundant floor fixings
- Mechanical diamond grinding of the existing concrete
- Multiple grinding stages across exceptionally hard areas
- Cleaning and preparation of every bolt hole
- Filling damaged areas using specialist epoxy repair mixes
- Regrinding the completed repairs to blend them into the existing slab
- Industrial vacuuming to remove dust and surface contamination
- Application of an oil-tolerant epoxy primer
- Application of a 100% solids industrial epoxy topcoat
Concrete Preparation and Epoxy Repairs
Effective preparation was essential to the performance of the new flooring system.
The entire 1,600m² floor was mechanically diamond-ground to remove weak surface material, contamination and previous coatings while creating the correct surface profile for the epoxy system.
Each redundant bolt was removed before the remaining hole was cleaned and filled with a high-strength epoxy repair mix. Once cured, the repaired areas were reground to leave them flush with the surrounding concrete.
Several sections required repeated grinding passes because of the hardness and condition of the existing industrial slab.
Oil-Tolerant Epoxy Primer
An oil-tolerant epoxy primer was selected because the floor was inside a previously used industrial building.
Industrial concrete can retain traces of oils and contaminants that may not be visible from the surface. Using an OT primer provided additional protection and helped create a reliable bond between the prepared concrete and the new epoxy topcoat.
100% Solids Epoxy Topcoat
Following preparation, repairs and priming, the floor received a 100% solids epoxy topcoat.
This produced a seamless and hard-wearing industrial finish designed to withstand regular traffic, demanding working conditions and ongoing operational use. The completed system also created a cleaner, more uniform surface that is considerably easier to maintain than the original damaged concrete.
The Result
Despite the difficult conditions, extremely hard concrete and the scale of the repair work, Shier Coatings successfully completed the 1,600m² industrial floor refurbishment.
The finished floor provides:
- A strong and durable epoxy surface
- Improved protection for the concrete slab
- A clean and professional appearance
- Easier cleaning and maintenance
- A seamless finish suitable for an industrial environment
- Long-term performance under regular operational traffic
The project demonstrates the importance of thorough mechanical preparation, proper epoxy repairs and selecting the right primer for an existing industrial concrete floor.
Industrial Epoxy Flooring in Newport and South Wales
Shier Coatings provides industrial epoxy flooring, concrete preparation and floor repair services throughout Newport, Cardiff, South Wales and across the UK.
Our services include diamond grinding, industrial floor repairs, epoxy coatings, polyurethane flooring, self-levelling resin systems and complete refurbishment of damaged concrete floors.
Contact Shier Coatings to discuss an upcoming industrial flooring project or arrange a site assessment.
