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Project Story
High-Efficiency Epoxy and Water-Based Polyurethane System for Building Materials Plant Renovation in Sweden
KAIDA Paint delivered a comprehensive industrial coating solution for the renovation of a large-scale building materials processing facility in Sweden. This integrated project combined a heavy-duty epoxy flooring system with a high-performance water-based polyurethane topcoat, alongside specialized roof and wall protective coatings, meeting the high durability and environmental standards of the European market within a tight 12-day schedule.
Client Challenge
The facility required a total surface overhaul to withstand heavy industrial processing within an accelerated 12-day window.
The aging building materials processing plant faced severe surface deterioration across its floors, walls, and roofs due to years of high-impact industrial activity. To prepare for the facility’s renovation, the client demanded a high-performance, integrated coating solution that could provide dust suppression, mechanical strength, and UV resistance. The primary hurdle was executing this large-scale project across 7,200 m² while adhering to a strict 12-day construction schedule before the restart of operations.
Rapid Execution on a Massive Scale
Renovating 7,200 m² of floor and building surfaces in just 12 days presented a massive logistical challenge. The project required a highly synchronized workflow and fast-curing materials to ensure that the floor, walls, and roof could be coated without any delay to the plant's production relaunch.
Substrate Stabilization and Dust Control
Years of processing building materials had left the original concrete and metal surfaces with extensive wear, cracks, and persistent dusting. A deep-penetrating primer system was critical to consolidate the weak substrate, ensuring maximum adhesion for the new coating while creating a dust-free environment for sensitive machinery.
Multi-Surface Performance Requirements
The facility required diverse protective properties: the floor needed to withstand heavy forklift traffic and mechanical impact, while the roof and walls required moisture and UV protection. The challenge was to implement a unified system—combining high-strength Epoxy and eco-friendly Water-based PU—to provide long-term durability against both mechanical and environmental stress.
Recommended Solution
A comprehensive surface coating package, engineered as a total-facility integrated system.
For the Sweden building materials plant renovation, KAIDA Paint supplied an all-in-one protection solution. This project required more than just flooring; it demanded a synchronized system combining a heavy-duty epoxy floor with an eco-friendly water-based polyurethane topcoat, alongside high-durability roof and wall coatings. This integrated approach ensures seamless protection and long-term structural integrity across the entire 7,200 m² facility.
Our technical team provided end-to-end support, from precise material calculation to application guidance. By coordinating the supply of specialized primers, mid-coats, and protective paints, we helped the client achieve a professional, uniform finish that meets the high environmental and performance standards of the European industrial market.
High-Performance Floor System
To solve the challenge of heavy mechanical stress, we implemented a multi-layer epoxy system (over 6 tons of material) finished with a Water-based PU topcoat. The high-penetration primer deep-seals the concrete, while the epoxy layers provide thickness and strength. The final PU layer adds exceptional scratch resistance and a UV-stable finish, ensuring the floor remains durable under frequent forklift traffic.
Total Envelope Protection
The solution extended beyond the floor to include 1,550kg of roof primer and over 3,600kg of specialized roof/wall paint. This “total envelope” strategy protects the plant from both internal processing humidity and external environmental exposure. The high-opacity wall paint and weather-resistant roof coating provide a clean, professional aesthetic while preventing corrosion and surface degradation.
Efficiency-Driven Supply & Support
Completing 7,200 m² in just 12 days required flawless material logistics and technical coordination. KAIDA Paint ensured the timely delivery of a 12-ton coating package, optimized for rapid application. Our integrated delivery model helped the site team synchronize flooring and painting phases, significantly reducing downtime and ensuring the plant could resume production on schedule.
Processus de construction
An optimized installation process designed for rapid 12-day renovation and long-term surface durability.
Step 01
Site Inspection and Substrate Evaluation
The 7,200 m² facility was thoroughly inspected to identify structural cracks, surface dusting, and moisture conditions across floors, walls, and roofs. This comprehensive assessment ensured the correct preparation method for the specific environmental conditions in Sweden.
Step 02
Mechanical Surface Preparation
Floor areas were mechanically ground to remove laitance, while roof and wall surfaces were cleaned to eliminate loose debris. This critical step created a sound, open-textured substrate, allowing the coating system to achieve maximum chemical and mechanical adhesion.
Step 03
Surface Repair and Crack Leveling
Visible cracks, holes, and damaged areas were repaired using high-strength epoxy mortar. Surface leveling was performed across the facility to improve flatness, providing a stable and uniform base for the following multi-layer protective coatings.
Step 04
Integrated Primer Application
1,920kg of specialized epoxy primer and 1,550kg of roof primer were applied to deep-seal the substrates. This layer helped consolidate the weakened surfaces, eliminate residual dust, and create a high-strength bonding foundation for the entire system.
Step 05
High-Build Coating Installation
A heavy-duty epoxy system (3,200kg topcoat) was installed to build floor thickness, while over 3,600kg of roof/wall paint were applied. This simultaneous process established the primary protective envelope, providing excellent load-bearing and weather resistance.
Step 06
Water-Based PU Performance
Finish 640kg of eco-friendly Water-Based Polyurethane was applied as the final floor layer. This UV-stable, ultra wear-resistant finish ensures the plant withstands daily forklift traffic and mechanical stress while maintaining long-term surface integrity and aesthetic quality.
Project Results
A high-performance, integrated facility renovation ready for building materials processing.
The Sweden processing plant renovation was successfully delivered within the ambitious 12-day shutdown window, transforming 7,200 m² of aged surfaces. By integrating a heavy-duty epoxy flooring system with a water-based polyurethane topcoat and specialized roof/wall coatings, the project significantly improved the facility’s structural durability, cleanliness, and professional aesthetic.
Superior Surface Integrity and Dust Suppression
The renovated system completely sealed the old concrete and building substrates, eliminating persistent surface dusting. This creates a cleaner, more controlled environment essential for high-quality building materials processing and protects sensitive machinery from grit contamination.
Unmatched Resistance to Heavy Industrial Traffic
The hybrid Epoxy and Water-based PU system provides a formidable shield against daily forklift movement, heavy equipment loads, and mechanical abrasion. This integrated floor-to-roof protection ensures long-term resistance to industrial wear, extending the facility's service life.
Sustainable and Compliant Production Environment
By utilizing low-VOC, water-based polyurethane technology, the facility now aligns with Sweden's strict environmental and safety standards. The new bright, easy-to-clean surfaces improve workplace safety, enhance lighting efficiency, and reduce long-term maintenance costs.
“Completing a 7,200 m² full-facility renovation in just 12 days was a remarkable achievement. KAIDA Paint's ability to coordinate a 12-ton material package and provide precise technical guidance was instrumental in our successful and timely production restart.”
FAQ
Frequently asked questions about epoxy and polyurethane coatings for industrial plant renovation projects.
The project utilized an integrated industrial coating package consisting of a heavy-duty epoxy flooring system finished with a water-based polyurethane topcoat, complemented by specialized high-durability roof and wall protective paints to provide total-facility protection.
Processing plants face heavy dust, mechanical impact, and environmental exposure. The epoxy system provides structural strength and dust control, while the specialized roof and wall coatings protect the facility’s envelope, ensuring a clean, durable, and professional production environment.
The water-based PU topcoat provides superior scratch resistance, UV stability, and a low-VOC profile. This is critical for meeting Sweden’s strict environmental standards while ensuring the floor remains easy to clean and maintains its performance under heavy industrial use.
We applied over 5,000kg of specialized roof primers and high-opacity wall/roof paints. This system sealed the old substrates, provided essential moisture protection, and improved the facility's overall aesthetic and structural integrity.
Yes. The combination of 3,200kg of epoxy topcoat and the high-performance PU finish is specifically engineered to withstand daily forklift movements, heavy equipment loads, and the intense mechanical stress typical of building materials processing.
Efficiency was achieved through optimized material logistics and a synchronized application process. By using fast-curing primers and coordinating flooring, wall, and roof coating tasks in parallel, we successfully met the client’s tight 12-day shutdown window.
No. The non-porous, seamless nature of the epoxy and PU surfaces makes the entire facility much easier to maintain. Standard industrial cleaning is sufficient to keep the surfaces in top condition, significantly reducing long-term maintenance costs.
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