Client: Denbighshire County Council
Location: Vehicle Repair & Maintenance Depot, St Asaph, Denbighshire
Date: December 2025
Our Role: Specialist Resin Flooring Contractor
Flowstone Industrial Flooring was appointed by Denbighshire County Council to refurbish the flooring at its vehicle repair and maintenance depot in St Asaph, North Wales.
The project, was completed in December 2025 and involved the installation of a high-build epoxy resin flooring system, concrete surface repairs, vehicle inspection pit coatings and safety line markings.
The depot is currently used daily for the inspection, servicing and repair of council vehicles. With regular vehicle movements and ongoing maintenance activities, the workshop required a durable, easy-to-clean floor capable of meeting the practical demands of a busy operational environment.
Our specialist epoxy flooring team carried out mechanical preparation of the existing concrete, completed localised repairs and applied a two-coat industrial epoxy resin system. The works also included coating the vehicle inspection pit walls and reinstating markings to identify working areas and improve workshop safety.
Flooring Requirements for a Council Vehicle Maintenance Depot
Vehicle repair workshops place considerable demands on their flooring. Heavy vehicles, maintenance equipment, regular cleaning and the potential for contact with oils and other workshop contaminants all influence our choice of a suitable floor coating.
At the Denbighshire County Council depot, the existing concrete floor required refurbishment to provide a more durable and manageable working surface.
The client needed a flooring solution that would improve cleanliness, support daily maintenance activities and provide a finish appropriate for an operational vehicle workshop.
Several requirements influenced the project:
- A hard-wearing floor coating suitable for regular vehicle movements.
- A chemical-resistant finish appropriate for a vehicle maintenance environment.
- A smooth, easy-to-clean surface to support workshop housekeeping.
- Protection for vehicle inspection pit walls.
- Clearly defined working areas, vehicle bays and pedestrian walkways.
- Installation and curing procedures suitable for a winter project.
The work was completed during December 2025, making careful adherence to the coating manufacturer’s preparation and curing requirements an important part of the installation.
The work was completed during December 2025, making careful adherence to the coating manufacturer’s preparation and curing requirements an important part of the installation.
Why High-Build Epoxy Resin Was Used for the Workshop Floor
Choosing suitable vehicle workshop flooring involves assessing how the space is used, the condition of the existing concrete and the performance required from the finished surface. For this project, an industrial high-build epoxy resin coating system was selected to provide a durable protective finish over the prepared concrete substrate.
Epoxy resin flooring is commonly specified for industrial workshops because it can provide a hard-wearing surface that is easier to clean and maintain than untreated concrete. At Denbighshire, the two-coat system was installed to meet the agreed specification for the vehicle maintenance facility.
The coating also provided a consistent finish across the workshop, allowing the reinstated safety markings to clearly distinguish operational areas. Rather than replacing the existing concrete floor, the refurbishment made use of the established substrate following mechanical preparation and localised repairs.
This approach allowed the flooring team to address surface defects before installing the new protective coating.
Preparing the Existing Concrete Workshop Floor
The condition of the concrete substrate has a direct influence on the performance of an epoxy resin floor coating. Before applying the new system, Flowstone mechanically prepared the existing workshop floor using shot-blasting equipment.
Shot blasting removes existing coatings, surface contamination and weak material while producing a suitable profile for the subsequent resin application.
The preparation process covered the full floor area, with additional diamond grinding and angle grinding carried out where required. Our team also identified and repaired localised defects in the concrete substrate.
These repairs were prepared to ensure compatibility with the new epoxy resin system.
The preparation works included:
- Mechanical shot blasting of the existing concrete flooring.
- Removal of previous coatings and surface contaminants.
- Localised diamond grinding to achieve the required surface profile.
- Angle grinding around areas requiring more detailed preparation.
- Repair of identified defects in the concrete substrate.
- Preparation of repaired sections before resin application.
Completing these stages before coating helped establish a suitable surface for the new flooring system.
For commercial vehicle workshops, preparation is an important consideration when refurbishing existing concrete rather than installing an entirely new floor.
Installing the Two-Coat Epoxy Resin Flooring System
Once the concrete preparation and repairs were complete, Flowstone began applying the industrial high-build epoxy resin coating. The installation consisted of two coats, with each application carried out in accordance with the agreed specification and manufacturer guidance.
The first coat was applied to the prepared concrete surface and allowed to cure for the recommended period before further coating work commenced. Observing the specified overcoating interval was particularly important during the December installation, when site conditions could influence curing.
Following the required curing period the second coat of high-build epoxy resin was applied to achieve the specified finish and durability, with the completed coating provided an easy-to-maintain surface suited to the daily activities of the vehicle repair depot.
After the installation, the flooring system was protected from water ingress for a minimum of seven days, with curing managed in accordance with the manufacturer’s technical data sheets. These procedures helped ensure that the completed flooring was installed under the conditions required by the specified system.
Vehicle Inspection Pit Coatings and Safety Line Markings
The project extended beyond the main workshop floor to include the vehicle inspection pits and operational safety markings. The Inspection pits are an important part of many commercial vehicle maintenance facilities, allowing technicians to access the underside of vehicles during inspection and servicing. The walls can be exposed to workshop dirt, moisture and contaminants, making surface protection and cleanability important considerations.
As part of the Denbighshire refurbishment, Flowstone applied protective coatings to the vehicle pit walls to improve their finish and make routine cleaning easier. The team also reinstated line markings which clearly identify vehicle bays, pedestrian walkways and operational areas throughout the workshop. Clearly defined markings help staff recognise working areas and support safer movement around maintenance activities.
The combination of coated pit walls and renewed floor markings provided a more organised working environment alongside the refurbished epoxy flooring.
Completing the Workshop Flooring Refurbishment in December 2025
The refurbishment was delivered during December 2025, requiring the team to manage preparation, application and curing in accordance with the manufacturer’s instructions. The work followed a defined sequence, beginning with mechanical preparation and concrete repairs before progressing to the two-coat resin installation.
The vehicle pit wall coatings and safety line markings formed part of the finishing works and the completed installation was protected during the required curing period before the flooring was returned to its intended operational use.
All works were completed in accordance with the agreed specification.
Completed Workshop Flooring at Denbighshire County Council
The completed project provided Denbighshire County Council with a refurbished vehicle maintenance workshop floor designed for the demands of daily servicing and repair activities. The high-build epoxy resin system created a hard-wearing, easy-to-clean surface over the prepared concrete substrate.
Coating the inspection pit walls improved their protection and cleanability, while the reinstated line markings helped define working areas throughout the facility.
Project summary included:
- Completion of the flooring refurbishment within desired timeframe.
- Installation of a two-coat industrial high-build epoxy resin system.
- Mechanical preparation and localised repair of the existing concrete floor.
- Protective coatings applied to vehicle inspection pit walls.
- Reinstated line markings identifying bays, walkways and operational areas.
- A durable, easy-to-maintain floor finish suitable for vehicle maintenance activities.
