“Heavy Metal” – Hygienic Flooring

Client Requirements

When a leading vegan food manufacturer in Gloucestershire required a robust, hygienic flooring solution for their kitchen produce area, Zenith were called in to deliver a high-performance system over an unusually challenging subfloor — a raised steel plate construction.

Project Challenges

The client needed a joint-free surface that would be hygienic, easy to clean, slip resistant, and flexible enough to accommodate potential movement in the underlying steel plates. The metal substrate ruled out traditional heavy preparation methods and demanded a specialist approach to ensure long-term adhesion and performance.

Overview of Works

After assessing the substrate and performance requirements, we specified a self-smoothing polyurethane system – Pumadur SL – topped with Pumadur DD in a matt finish for enhanced slip resistance and durability.

Preparation involved careful mechanical abrasion to lightly key the steel plates without compromising their structure. This was followed by the application of primer to ensure a strong bond between the metal and the resin system.

The polyurethane system was installed at a nominal 4mm thickness and finished with a matt polyurethane topcoat, providing the flexibility and seamless finish the environment demanded.