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Project Story
High-Performance Epoxy Flooring and Polyurethane Wear-Resistant System for Battery Plant Renovation in Hungary
KAIDA Paint delivered a complete industrial flooring solution for the renovation of a battery manufacturing facility in Hungary. The project combined a heavy-duty epoxy flooring system with a polyurethane ultra wear-resistant topcoat to meet the strict requirements of battery production environments.
Client Challenge
The factory needed a safer, more durable production floor without delaying its renovation schedule.
The existing concrete floor showed unevenness, surface dusting, cracks, and worn areas caused by years of heavy industrial use. For a battery manufacturing environment, the client required a flooring system that could improve workplace safety, control dust, resist chemical exposure, and withstand frequent forklift traffic, while still being completed within a tight project timeline.
Surface Defects and Dusting Concrete
The old substrate had visible cracks, laitance, loose surface particles, and weak spots. These issues caused continuous dust generation and created a high risk of poor adhesion for any new coating system.
Strict ESD Safety Requirements
In battery production areas, uncontrolled static discharge can damage sensitive components and increase operational safety risks. The floor system needed to provide stable, long-term electrostatic discharge protection across the facility.
Resistance to Chemical and Mechanical Stress
The renovated floor had to withstand daily forklift movement, equipment loads, industrial cleaning, and possible electrolyte spills, while maintaining strong surface integrity and long-term wear resistance.
This project in Hungary involves an 11,000㎡ old floor renovation for KDL, a Shenzhen‑listed Chinese manufacturer of precision structural parts for power & energy‑storage lithium batteries. Serving global leaders like CATL, BYD, LG Energy Solution, Panasonic, Tesla, and Samsung Battery, KDL reported 2024 annual revenue of RMB 12.03 billion. Our scope: full removal of the existing epoxy‑quartz floor, substrate repair & reinforcement, and installation of a new polyurethane ultra‑wear‑resistant floor system.
Recommended Solution
A complete epoxy and polyurethane flooring package, engineered as one integrated system.
For the Hungary battery plant renovation, KAIDA Paint supplied a high-performance flooring solution combining a heavy-duty epoxy system with a polyurethane ultra wear-resistant topcoat. The system was designed to restore the aged concrete substrate, improve surface strength, provide long-term dust control, and deliver reliable protection against daily mechanical wear and chemical exposure.
Our technical team supported the project from material selection and system design to application guidance, on-site supervision, and final quality inspection, helping ensure a consistent, durable finish across the entire production area.
Advanced Substrate Treatment
To solve the challenges of dusty, uneven, and weakened concrete, the floor was mechanically prepared and treated with a high-penetration epoxy primer. This layer helped seal the substrate, strengthen the surface, reduce residual dust, and create a strong bonding foundation for the following coating layers.
Integrated Performance System
The flooring system combined high-build epoxy layers with a polyurethane ultra wear-resistant finish to meet the demanding requirements of battery manufacturing. It provided excellent abrasion resistance, chemical resistance, dust-proof performance, and stable long-term protection under frequent forklift traffic, equipment movement, and industrial cleaning.
Project Delivery Support
KAIDA Paint provided a complete material and construction support package for the Hungary site, including system recommendation, product supply, application instructions, and technical supervision. This integrated delivery model helped the contractor complete the renovation efficiently while maintaining reliable coating quality and compliance with industrial flooring standards.
From Old Epoxy to Ultra-Wear-Resistant Floor – KDL Hungary Project Construction Process
Applying the Polyurethane Ultra-Wear-Resistant Sealing Coat
Construction Process
A controlled installation process designed for fast renovation and long-term floor performance.
Step 01
Site Inspection and Substrate Assessment
The existing concrete floor was inspected to identify cracks, weak areas, surface dusting, contamination, and moisture conditions. This helped define the correct preparation method and coating system for the renovation.
Step 02
Mechanical Grinding and Surface Cleaning
The old surface layer was mechanically ground to remove laitance, loose particles, and weak concrete. Dust and debris were then thoroughly cleaned to create a sound, open-textured substrate for primer application.
Step 03
Crack Repair and Surface Leveling
Cracks, holes, and damaged areas were repaired with epoxy mortar. Uneven sections were leveled to improve flatness and provide a stable base for the following coating layers.
Step 04
Epoxy Primer Application
A high-penetration epoxy primer was applied to seal the concrete, strengthen the substrate, and improve adhesion between the old floor and the new coating system.
Step 05
Epoxy Intermediate Layer Installation
A heavy-duty epoxy intermediate layer was installed to build system thickness, enhance load-bearing performance, and improve resistance to daily forklift traffic and equipment movement.
Step 06
Polyurethane Ultra Wear-Resistant Topcoat
A polyurethane ultra wear-resistant finish was applied as the final protective layer, providing excellent abrasion resistance, chemical resistance, easier cleaning, and long-term surface durability.
Project Results
A safer, cleaner, and more durable production floor ready for battery manufacturing
The Hungary battery plant renovation was completed within the planned shutdown window, delivering a high-performance industrial floor designed for long-term production use. By combining a heavy-duty epoxy flooring system with a polyurethane ultra wear-resistant topcoat, the project significantly improved floor strength, cleanliness, chemical resistance, and daily traffic durability.
Improved Surface Strength and Dust Control
The renovated floor sealed the old concrete substrate and reduced surface dusting, creating a cleaner production environment for battery assembly and sensitive equipment operation.
Enhanced Resistance to Wear and Chemicals
The epoxy and polyurethane system provided strong protection against forklift traffic, equipment movement, industrial cleaning, and potential electrolyte spills, helping extend the service life of the floor.
Safer and More Efficient Production Environment
The new floor surface improved workplace safety, supported easier cleaning and maintenance, and helped the facility meet the operational requirements of modern EV battery manufacturing.
“The floor was delivered exactly on schedule. The KAIDA team’s ability to coordinate material logistics and complex installation details through a single point of contact was instrumental in our successful facility launch." — Facility Project Manager, Hungary”
VANLIGA FRÅGOR
Frequently asked questions about epoxy and polyurethane flooring for battery plant renovation projects.
The project used a heavy-duty epoxy flooring system combined with a polyurethane ultra wear-resistant topcoat. This system was selected to improve surface strength, dust control, chemical resistance, and long-term durability.
Epoxy flooring provides strong adhesion, high mechanical strength, and excellent dust-proof performance, making it suitable for production areas with frequent equipment movement, forklift traffic, and strict cleanliness requirements.
The polyurethane ultra wear-resistant topcoat acts as the final protective layer. It enhances abrasion resistance, improves resistance to cleaning agents and chemical exposure, and helps maintain a smooth, easy-to-clean surface over time.
The existing concrete surface was mechanically prepared, repaired, and sealed with a high-penetration primer. This helped reduce dusting, strengthen weak areas, and create a reliable bonding base for the new coating system.
Yes. The epoxy and polyurethane system was designed to provide chemical resistance against common industrial chemicals and potential electrolyte spills, helping protect the concrete substrate and support safer daily operations.
Yes. The heavy-duty epoxy build-up and polyurethane wear-resistant finish were designed to withstand frequent forklift movement, equipment loads, and daily industrial use.
No. The finished surface is seamless, dust-resistant, and easy to clean. Regular sweeping, wet cleaning, and proper chemical spill handling can help maintain its appearance and performance.
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