A Coalville company has completed a £300,000 project using flooring made of recycled plastic.

The job was part of a £15million refit for Doncaster-based Polypipe, one of Europe's largest and most innovative manufacturers of piping, underfloor heating and energy-efficient ventilation, which is undergoing one of the largest single investments in its 40-year history.

As part of the refurbishment at its Edlington site, more than £300,000 has been invested in new flooring in its two production halls - home to plastic injection moulding machinery.   

Using innovative Abaplas technology from award-winning Coalville-based resin flooring company, Abacus Flooring Solutions, 33,000 sqft of flooring has been installed.

The same flooring systems - used from recycled plastics - have been installed at venues including Wembley stadium and JCB's headquarters in Staffordshire.  

As part of the flooring installation, the team at Abacus Flooring Solutions used 2800kgs of resin coating, 1275kgs of recycled plastic and two eight yard skips of empty resin containers were recycled.  

Nick Megson, managing director of Abacus Flooring Solutions, founded the firm in 2020 after more than 30 years in the resin flooring industry.   

He said: "We are delighted to have been able to have not only provided a fantastic product to a much-valued customer as part of their refurbishment, but also to have provided a product that runs parallel to their sustainability goals. 

The Polypipe site in Doncaster. Photo: Supplied

"By re-using plastic, we are able to save thousands of tonnes of plastic from going to landfill, which is extremely satisfying."   

Darren Fox, head of engineering at Polypipe, said: "We've got a vision to create a world-class plastic injection moulding facility and the product and service that Abacus Flooring Solutions offered us aligned perfectly with that vision.   

"We are really interested in the use of recycled plastic in our flooring because it aligns perfectly with our sustainability goals and targets."

Darren added that the first phase of the flooring installation, in production hall one, involved the complete refurbishment of an older building, while phase two, in hall two, saw Abacus workers laying flooring around production, so Polypipe productivity never ceased.   

He added: "It's really great to show visitors and investors around the facility and actually tell them that they are walking on recycled plastic. "It's been an absolutely fantastic partnership between us and Abacus Flooring Solutions."   

To find out more about Abacus Flooring Solutions, click HERE.