Solving Moisture and Oil Contamination Problems in a Historic Foundry Floor

The Challenge: Restoring a Heavily Worn, Oil-Contaminated and Moisture-Damaged Concrete Floor

The former Copperworks foundry—previously known as Leeds Copperworks and later Yorkshire Copperworks—has played a significant role in British industrial history. At its peak, the site employed over 5,000 people and contributed to major developments, including the invention of the Yorkshire fitting and supplying materials for shipbuilding repairs during World War I.

After closing in 1980, the 90-year-old facility required extensive refurbishment to support its transformation into a modern warehousing and distribution centre.

A key challenge was the condition of the existing 24,400 square metre concrete floor. The substrate was in varying states of disrepair, with multiple layers of legacy coatings, embedded iron tracks, heavy wear and tear and widespread oil contamination. In addition, moisture was present in several areas, increasing the risk of coating failure and delamination.

To meet the demands of a modern industrial environment, the flooring system needed to deliver strong adhesion across compromised substrates, withstand heavy use and provide a clean, durable surface suitable for warehouse operations. Surface preparation was critical, requiring diamond grinding and shot blasting to remove contaminants and create a suitable profile for installation.

The Solution: Installing an Oil- and Moisture-Tolerant Epoxy Resin Flooring System

Following a detailed site assessment, Sherwin-Williams specified a multi-layer epoxy resin system designed to address both oil contamination and moisture-related risks.

An oil-tolerant primer was applied across the prepared substrate to prevent delamination and ensure reliable adhesion, even in areas affected by long-term contamination. In sections where moisture had been detected, Resuprime MVT—a two-component epoxy resin membrane—was installed to act as a moisture-tolerant barrier and stabilise the substrate.

The system was then finished with two coats of Resuflor HB, a high-build, low-odour epoxy resin industrial floor coating. This product was selected for its ability to deliver high impact and wear resistance, along with strong adhesion to varied substrates, including aged concrete. Its high-gloss finish also enhances light reflectivity, improving visibility within large industrial spaces.

Installation was carried out by Monarch Flooring for the client Allied Glass. The system is available with a range of compatible primers and colour options, allowing it to be tailored to different operational requirements.

The Results: A Durable, High-Gloss Industrial Floor Supporting Modern Warehouse Operations

The completed flooring installation formed a key part of the wider redevelopment of the site, which included re-roofing and re-cladding works. The transformation resulted in a modern warehousing and distribution facility spanning approximately 300,000 square feet for owners Towngate plc.

The new epoxy resin flooring system provides a sound, durable surface capable of withstanding heavy operational use while remaining easy to clean and maintain. By addressing both oil contamination and underlying moisture issues, the system delivers long-term performance and reliability across the entire facility.

Matthew Jones of Jones Hargreaves building consultants, who led the project, commented:
“A solution was required to coat the floor to provide a sound surface which the tenant could keep clean easily. Sherwin-Williams has provided a first-class solution, providing a suitable specification and details of the guarantee within a very short space of time to assist us in meeting the programme to a very high standard.”

The result is a resilient, high-performance flooring system that supports the building’s new purpose while preserving the legacy of one of Britain’s historic industrial sites.