590m² Industrial PU Resin Flooring Project in Derby
Shier Coatings completed a 590m² industrial resin flooring refurbishment at a facility in Derby.
The existing concrete floor had been mechanically ground before our arrival. Once the surface was fully exposed, extensive porosity, cracks, pits, localised damage and differences in slab height became apparent.
The project required substantial remedial preparation before the specified polyurethane self-smoothing flooring system could be installed.
Project Overview
- Location: Derby
- Floor area: Approximately 590m²
- Environment: Industrial facility
- System: Polyurethane self-smoothing resin flooring
- Reinforcement: Approximately 200m² of floor bandaging
- PU flooring material: 128 bags
- Primer: Two complete applications of OT Primer
- Finish: Two polyurethane matt sealer coats
- Additional work: Local repairs, ramp formation and joint refurbishment
The Existing Floor
Although the concrete had been mechanically ground before Shier Coatings attended, the preparation exposed a highly porous and irregular industrial slab.
The floor contained numerous cracks, open pits, local depressions and damaged areas. There was also a substantial difference in height between sections of the concrete, requiring a ramped transition to be formed.
The open surface absorbed a significant quantity of primer and produced porosity bubbles during the initial application. This required further mechanical preparation and an additional complete primer coat before the polyurethane flooring could be installed.
Repairs and Reinforcement Bandaging
Localised repair patches were completed throughout the floor to address pits, damaged areas and surface irregularities.
Approximately 200m² of reinforcement bandaging was installed across cracks, vulnerable sections and existing movement lines. The reinforcement was embedded into the resin system to provide additional support across the repaired areas.
A ramped transition was also formed where sections of the existing concrete met at different heights.
Two OT Primer Applications
The prepared floor received two complete applications of oil-tolerant OT Primer.
Following the first application, the surface was mechanically abraded using an STR machine and thoroughly vacuumed. This removed raised porosity bubbles, created a suitable mechanical key and prepared the floor for the second primer coat.
The additional priming helped seal the unusually porous concrete and provided a consistent foundation for the polyurethane flooring system.
PU Self-Smoothing Resin Flooring
A total of 128 bags of polyurethane self-smoothing flooring material was installed across the 590m² area.
The material was continuously mixed, distributed across the floor, regulated to the specified thickness and spike-rolled during installation.
The completed PU flooring created a seamless, hard-wearing industrial surface designed to withstand regular operational traffic while remaining considerably easier to clean and maintain than the original concrete.
Two PU Matt Sealer Coats
Following curing and inspection of the self-smoothing floor, local imperfections were filled and prepared before the final finishing stages.
Two polyurethane matt sealer coats were applied throughout. These coats produced a consistent low-sheen appearance and provided additional protection to the completed resin flooring system.
Joint Refurbishment
Three principal floor joints were recut following completion of the resin installation.
The joints were cleaned and filled using a flexible resin jointing material, allowing the original movement lines to remain defined within the completed floor.
The Finished Industrial Floor
The completed installation transformed a heavily repaired and exceptionally porous concrete slab into a clean, seamless and professional industrial floor.
The finished system provides:
- A durable polyurethane resin surface
- Improved protection for the existing concrete
- A seamless and easy-to-maintain finish
- Reinforcement across cracked and vulnerable areas
- Refurbished movement joints
- A consistent matt appearance
- A practical surface for an operational industrial environment
This Derby project demonstrates the importance of inspecting the exposed substrate, responding correctly to unexpected porosity and completing the necessary repair and priming stages before installing an industrial resin flooring system.
Self-Smoothing Resin and Existing Floor Levels
A polyurethane self-smoothing floor is designed to create a seamless resin surface. It is not a structural levelling screed and will generally follow the broader profile, falls and undulations of the existing concrete substrate.
Where substantial correction of floor levels is required, a separate levelling or screeding system should be specified before the resin finish is installed.
Industrial Resin Flooring Contractors in Derby
Shier Coatings installs industrial resin flooring throughout Derby, Derbyshire, the East Midlands and across the UK.
Our services include:
- Industrial epoxy flooring
- Polyurethane self-smoothing floors
- Concrete grinding and surface preparation
- Crack and damaged-concrete repairs
- Industrial expansion-joint refurbishment
- Anti-slip resin flooring
- Safety walkways and floor demarcation
Every project is assessed individually so that the preparation method, repairs and resin system suit the condition of the existing concrete and the operational requirements of the facility.
FREQUENTLY ASKED QUESTIONS
What type of resin flooring was installed on this Derby project?
A polyurethane self-smoothing resin flooring system was installed across approximately 590m². The system included extensive repairs, reinforcement bandaging, two OT Primer applications, the PU flooring layer and two matt polyurethane sealer coats.
Why were two primer coats required?
The mechanically prepared concrete was exceptionally porous and absorbed a substantial amount of the initial primer. Mechanical abrasion and a second primer application were required to seal the open substrate and create a consistent base for the PU flooring.
Can resin flooring be installed over cracked concrete?
Cracked concrete can often receive a resin flooring system, but the cracks must first be inspected and appropriately repaired or reinforced. This project required approximately 200m² of reinforcement bandaging across cracks and vulnerable areas.
Is self-smoothing resin the same as a floor-levelling screed?
No. Self-smoothing resin creates a seamless surface but is not designed to correct major slab undulations or substantial differences in level. Significant height correction requires a separate levelling or screeding system.
Does Shier Coatings install industrial resin flooring in Derby?
Yes. Shier Coatings undertakes industrial resin flooring projects throughout Derby, Derbyshire, the East Midlands and across the UK.
Contact Shier Coatings to discuss an industrial resin flooring project in Derby or arrange a site assessment.
