Resgen Case study
Car Service Centre Resin Flooring Transformation, Horsham
Project Snapshot:
Location: Horsham, West Sussex
Property type: Commercial Car Service Centre
System installed: Epocoat High Build (HB)
Repairs: Localised dig-outs filled with epoxy mortar
Floor area: Approx. 240m²
Completion time: 3 days
Client: Peter Copper Motor Group
The challenge
Industrial resin flooring is only as good as the concrete beneath it, and this unit’s floor had taken years of wear. It was cracked, pitted in places, and broken up enough in several areas that the damaged concrete had to come out altogether.
The floor also had to work harder than a typical garage. The client needed a surface that wouldn’t generate dust and could stand up to vehicle movements and heavy foot traffic across the whole area. That is exactly what industrial resin flooring is built for, provided the substrate is properly repaired and prepared first.
The solution
We recommended a two-coat Epocoat HB high build epoxy system, applied over a fully prepared and repaired substrate. A high build industrial epoxy seals the concrete, which removes the dusting problem. It also gives a smooth, even, hard-wearing finish suited to vehicles and constant footfall.
Because the damage went deeper than the surface, the repairs were part of the specification from the start. We didn’t coat over them.
Why Epocoat hb
Epocoat HB is a solvent-free, high build epoxy resin floor coating, designed for demanding industrial and commercial environments. Applied by roller, it bonds strongly to properly prepared concrete and cures to a seamless, coloured gloss finish. That finish seals the surface, which stops dusting. It also resists abrasion and everyday chemical exposure, and it’s hygienic and easy to clean.
This makes it a dependable choice for warehouses, workshops, manufacturing areas and other commercial spaces that see vehicles and heavy foot traffic. Because it builds a thicker film than standard coatings, it also helps bridge minor surface imperfections. For areas where grip matters, a slip-resistant version is available, and ResGen can add anti-slip where the site needs it.
The process
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1. Diamond grinding
Floor and hand-held grinders, connected to vacuum recovery to keep dust down, removed contaminants and laitance and opened up the concrete. This gives the resin a sound, keyed surface to bond to.
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2. Concrete repairs
Areas of broken concrete were dug out and filled with epoxy mortar, so the floor was solid and level before coating.
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3. Base coat and remedial repairs
The first coat of Epocoat HB was rolled across the whole floor. Any remaining imperfections were then dealt with before the second coat.
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4. Top coat
A second coat of high build industrial epoxy was rolled on in the client’s chosen colour.
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5. Anti-slip, where needed
Polymer bead anti-slip can be added in specific areas, following FeRFA slip-resistance criteria.
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The Outcome
The Results
The unit now has a seamless, dust-free floor in place of the cracked and crumbling concrete. It’s strong enough for daily vehicle and foot traffic and easy to keep clean.
The finished floor delivers:
A dust-free surface that stops the concrete shedding
A hard-wearing finish for vehicles and heavy foot traffic
Repaired and reinforced areas where the concrete had broken up
A smooth, easy-to-clean, low-maintenance surface
Slip resistance where the site needed it
A professional appearance in a working environment
