Levelling and Restoring a Damaged Factory Floor for Modern Manufacturing

The Challenge: Upgrading an Uneven, Contaminated Concrete Floor for Industrial Production

A coatings factory in Yorkshire needed to upgrade its former solvent store to support new manufacturing processes. The existing concrete floor was uneven, worn and contaminated, making it unsuitable for use as a modern production area.

To meet the operational demands of the upgraded facility, the floor needed to be transformed into a level, durable working surface capable of withstanding heavy loading and continuous industrial traffic. Achieving a seamless finish was also essential to support efficient production and meet health and safety standards.

Sherwin-Williams specialists worked closely with the client and contractor, Monarch Resin Floors, to develop a solution that would deliver long-term performance while remaining within the project’s required timeframe. The challenge was not only to restore the substrate but to create a high-quality, modern industrial floor that could perform reliably under demanding conditions.

The Solution: Pump-Applied Screed and Multi-Layer Epoxy Resin Flooring System

Following thorough preparation of the concrete substrate, a multi-layer flooring system was specified using products from the Sherwin-Williams range of industrial coatings and screeds.

Primer coats of Resuflor™ WB and Resuprime™ MVT were first applied to establish a clean, stable and well-bonded substrate. These layers helped address contamination issues while preparing the surface for further build-up.

To achieve the required level surface, two coats of Sher-Crete™ BU cementitious underlayment screed were applied by pump. This method enabled rapid installation across the area while delivering excellent levelling performance, creating a smooth and consistent base suitable for industrial use.

Once the screed had cured, Resuprime™ ST pure epoxy resin primer was applied, followed by Resuflor™ SLX, a self-levelling epoxy resin installed at approximately 3 mm thickness. This layer provided a seamless, smooth surface with strong mechanical properties and high durability.

To complete the system and introduce anti-slip performance, a roller-applied coat of Resuflor™ HB coloured high-build epoxy resin was installed, incorporating an aluminium oxide aggregate. This final layer enhanced safety while maintaining the system’s overall durability and resistance to wear.

The Results: A Seamless, Durable Industrial Floor Built for Heavy-Duty Use

The completed flooring system successfully transformed the former solvent store into a modern, high-performance production space. The new surface provides a seamless, level and robust foundation capable of supporting heavy industrial traffic and ongoing manufacturing operations.

The system not only meets health and safety requirements but also enhances operational efficiency by delivering a clean, easy-to-maintain working surface. Its durability ensures long-term performance, reducing the need for ongoing repairs or maintenance.

The result is a reliable, high-quality flooring solution that supports modern manufacturing demands while delivering a significant upgrade over the original substrate.