Single-source industrial flooring specialist Kemtile has met one of its heaviest-duty challenges in years by laying a high-performance, power-trowelled epoxy floor mortar to withstand traffic from 70-tonne tanks manufactured by a Shropshire-based defence engineering company. 

Kemtile – a division of the international flooring manufacturing business, Stonhard – provided a robust flooring solution for Rheinmetall BAE Systems Land (RBSL). RBSL is a joint venture between BAE Systems and  Rheinmetall providing military vehicle design, manufacture and support.

The Warrington-based flooring firm installed 19,000 sq metres of its well-known and extensively used, Stonclad GS epoxy mortar on the main production floors at the site in Telford. 

The flooring installation is part of RBSL’s £20m internal investment programme to improve infrastructure and create a world-class manufacturing facility to deliver key armoured vehicle programmes. 

Time-lapse video (© Copyright RBSL 2021) of the floor being laid is phase one of a 10-phase project, which is now fully completed.

Prior to Kemtile’s involvement, RBSL had manoeuvred the heavyweight vehicles over a painted concrete floor.

To demonstrate the benefits of a more resilient approach, the technical services team from Kemtile took RBSL engineers to other companies to view floors that had been laid eight to 10 years earlier in similar heavy-duty environments. 

After a series of site visits and some extensive research, RBSL upgraded to the long-lasting Stonclad GS epoxy mortar alternative, also taking advantage of another specialist product from Kemtile – Stonproof CT5 to mitigate future cracking risks.

Steve Lyon, Technical Services Manager from Kemtile, said the project had been a hugely satisfying one. He added: “RBSL now has a durable flooring solution which can properly withstand years of what is probably the ultimate in heavy duty traffic. Tanks and other military vehicles can roll over this floor with confidence.”

Andy Lovatt, Senior Facilities Engineer at Rheinmetall BAE Systems Land (RBSL) said: “Installing a new floor in a 60-year-old factory, while maintaining production activity, has been a unique and logistically challenging project for RBSL and Kemtile.

“Kemtile was selected because of its proven experience in delivering market-leading flooring products. The new floor will provide a long-term, durable surface which greatly improves the environment and reduces maintenance costs. It is transforming the factory and we are delighted with the quality of the finished product.”