Enhancing safety and cutting costs

An epoxy grit floor at Caparo's Wrexham site was highly susceptible to wear due to the use of water in the manufacturing processes.The floor needed full replacement every 8-12 months due to grit detaching and the floor surface becoming slippery – which at an annual cost of £4300, represented avoidable expenditure.

The Caparo team called in strategic partner Buck & Hickman to identify a solution which would help extend the life of the existing flooring, while simultaneously reducing the downtime and inconvenience caused by the frequent replacement. A further key criterion was the health & safety of employees, with Caparo specifying non-slip flooring to minimise the risk of falls. 

Buck & Hickman believed the best course of action would be to cover the existing flooring surface with specialist, durable non-slip matting as Abbey Kelly, Buck & Hickman Key Account Manager explained: "We identified Ergodeck No-slip matting for our initial trial over a 10m² area as it had the additional benefit of anti-fatigue properties. Operatives working in the area agreed, finding it comfortable to stand on, and not a single slip or fall was reported over the course of the trial. The product also offers a three-year guarantee as its cleats (studs) are integrally moulded into the mat for a longer life, and at £150/m², the potential cost savings were clear.”

Based on the results of the trial coupled with the cost benefits, Caparo installed the Ergodeck matting throughout the site which has maximised health & safety for employees as well as eliminating the downtime associated with the replacement of the original floor. Caparo will also enjoy a considerable cost saving of £12,900 in epoxy grit replacement costs over the course of the three-year Ergodeck guarantee – with the potential for the matting to exceed its projected life.

Paul Boyes, Operations Manager of Caparo explained: "The wear of the epoxy grit floor had become a concern to us in certain areas of the plant, not just because of replacement costs, but because of the potential health & safety risks it posed to our workforce. However, Buck & Hickman’s expertise and clever thinking has resulted in a simple and cost-effective solution which combines reduced capital expenditure with a guarantee of no slips – protecting our employees and minimising disruption.”