Principality Stadium Cardiff

A major maintenance and upgrade programme at a national stadium in Cardiff required the refurbishment of an existing open basement area to create a functional plant room. The stadium, a high-profile venue hosting a wide range of major sporting and entertainment events, demanded a solution that could be delivered within a strict timeframe while ensuring durability and long-term performance in a high-traffic environment. The area had previously been exposed to external conditions and incorporated drainage falls, resulting in an uneven and inclined concrete subfloor that required levelling prior to the installation of mechanical equipment.

The project required approximately 220m² of floor area to be brought to a consistent level within a three-day programme. The varying profile of the existing substrate meant that levelling depths ranged from approximately 5mm at the highest points to 27mm at the lowest, with an average application depth of around 18mm. In addition to achieving a level surface, the system needed to provide sufficient strength and durability to support plant equipment, while allowing rapid progress to maintain the overall project schedule.

Preparation of the substrate was carried out using weberfloor 4716 primer, applied to regulate suction and ensure effective adhesion of subsequent screed layers. This created a stable and uniform base for the levelling system, helping to reduce the risk of defects and supporting consistent curing across the full application area.

The initial build-up layer was formed using weberfloor fibre 4310, a fibre-reinforced, self-smoothing levelling screed designed for renovation and base preparation. Installed across the full 220m² area within a short application window, the material provided the necessary build-up to correct substrate irregularities while delivering enhanced durability through fibre reinforcement. Suitable for application between 5mm and 50mm, the product also offers rapid strength development, allowing access for light foot traffic within a few hours of installation.

Following curing of the base layer, a further application of weberfloor 4716 primer was used to prepare the surface for the final wearing layer. weberfloor industry rapid 4655 was then applied as a high-performance, self-smoothing topping screed. Designed for industrial environments, this product provides a hardwearing and durable finish, suitable for areas subject to high traffic and mechanical load. Applied at thicknesses between 4mm and 15mm, it offers rapid drying characteristics, enabling light foot traffic within 1–2 hours and allowing final finishes to be applied after approximately 24 hours, depending on site conditions.

The combination of these systems enabled the full floor build-up to be completed within the three-day programme, despite the complexity of the existing substrate and the varying application depths required. The use of fast-drying, self-smoothing materials ensured that each stage could be progressed quickly, with minimal waiting time between layers, supporting efficient sequencing of works and reducing overall downtime.

The completed surface provided a level, durable and high-performance base suitable for the installation of plant equipment and subsequent resin finishes. The screed system also benefited from low dust technology, helping to reduce airborne dust during mixing and installation, improving working conditions and contributing to a cleaner, more efficient site process.

The integration of weberfloor 4716 primer, weberfloor fibre 4310, and weberfloor industry rapid 4655 delivered a robust and efficient flooring solution capable of meeting the demands of a high-profile commercial environment. The system provided a balance of speed, strength, and surface quality, enabling a complex refurbishment to be completed within tight time constraints while maintaining the performance standards required for long-term service.