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Tesco Express, Leigh on Sea, Essex

d2 Dura Grating Solid Top Retail Flooring | Case Study

Project: Tesco Express, Leigh on Sea, Essex, SS9

Contractor: Genco

Tesco Express shops are convenience stores averaging 200 square metres, stocking food and everyday essentials.  For this store refit in the East of England, experienced retail contractor GENCO was appointed as primary contractor for a range of works including ceiling works, painting and decorating and a rip out and installation of new retail flooring.

The existing flooring at the store consisted of a tiled floor surface and two base layers of 18mm plyboard which was badly rotten and in need of replacement due to leaks from the chiller cabinets. Although ply is in common usage across the convenience store sector, leakages leading to degradation of the subfloor are a regular occurrence, requiring subfloor replacement on average every 3 years.

With long term performance and value for its end customer in mind, GENCO chose Dura Composites to supply a material for the subflooring layer known as d2 Dura Grating Solid Top. Manufactured from durable and corrosion-resistant Glass Reinforced Polymer (GRP) to a patented design, the 41mm thick flooring was cost engineered to maximise performance versus the previous retail subfloor solution and to allow for easy installation of the planned Gerflor vinyl top layer walking surface.

Working in partnership with GENCO, Dura Composites completed an in-house fixing test to demonstrate the required 3.6kN Point Load compliancy, the ability to achieve a flush surface and the reduced installation time benefits versus ply. As a result, d2 Dura Grating Solid Top is now being rolled out across other Tesco stores.

Commenting on the Dura Composites products installed at Tesco Express Leigh on Sea, the Site Contracts Manager said:

As experts in reactive, planned and preventative maintenance services within the retail sector, we are always looking to deliver the highest possible standards for our end clients. We found Dura Composites to be an excellent supply chain partner for this retail flooring project thanks to their first-rate communication and collaborative approach.

 

With regular site visits, and access to extensive testing such as Point Load testing, we were confident that the Dura team shared our commitment to ensuring the subfloor solution met our exacting requirements.

 

The d2 Dura Grating Solid Top 41mm used on this project is highly durable and requires virtually no maintenance, meaning it offers excellent lifecycle benefits for our end client. The innovative lightweight design ensured speed of installation on site and negated the need to glue 2 sheets of plywood together, saving labour costs.

 

We look forward to utilising d2 Dura Grating subflooring on future projects.

Unlocking the Power of Composites for Your Retail Project

GRP composites can provide major design flexibility, time saving benefits and significant lifecycle advantages over traditional materials such as plywood, hardwood and concrete, and recent clarification of key standards areas such as fire performance have made them more accessible than ever. Tailored d2 Dura Grating is a new patent pending GRP grating series that takes structural flooring to the next level.

d2 Dura Grating offers outstanding safety, performance and durability and is more cost-effective than traditional GRP grating in almost every scenario. Available exclusively from Dura Composites, d2 Dura Grating Solid Top 41mm can be supplied as standard with properties such as strength, stiffness, weight and colour can be engineered by product design at the early stages of development and applications for GRP within the Retail Sector include GRP flooring, handrails, trench and duct covers, up and over staircases, utility screening and roof walkways.

Discover the benefits of d2 Dura Grating

Designed, developed and manufactured by Dura Composites, d2 Dura Grating offers outstanding safety, performance and durability and is more cost-effective than traditional GRP grating in almost every scenario.

It can be applied in all industries where GRP mesh grating is used today and has an industry-leading Class Bfl-s1 fire rating as standard (in accordance with BS EN 13501). As with all our grating, it can be supplied with a range of stainless steel clips, clamps and hold down fixings to suit all install scenarios.

A comprehensive range of load testing data is also available within our searchable Online Product Selector database to help you make decisions based on real data to ensure maximum safety for your project.

  • Micro Mesh: 23mm
  • Mini Mesh: 23mm, 35mm, 45mm & 55mm
  • Standard Mesh: 26mm, 38mm & 50mm
  • Solid Top (Covered): 29mm, 41mm & 53mm
Choose Your Grating Product >>

Contact our Specialist Industrial Team about our Composite Solutions

Call us on 01255 440290


Joe Hunt

Industrial Sales Manager


Ian Dennis

Industrial Sales Key Account Manager


Danielle Lewis

Industrial Sales Account Manager