Wall Cladding Coating Works at a Staffordshire Fitness Facility

D&D Coatings were recently engaged to undertake a comprehensive external wall cladding coating refurbishment programme at a steel-framed commercial gymnasium in Stafford, Staffordshire. The facility’s owner approached us having identified significant deterioration to the building envelope — a situation that, if left unaddressed, risked accelerating structural corrosion and presenting an increasingly poor first impression to prospective members.

From initial enquiry through to final sign-off, the project was managed and delivered to the exacting standards our clients have come to expect from D&D Coatings — on time, on budget and with minimal disruption to an operational business environment.

Client Brief & Specification

The client’s objectives extended beyond simple building maintenance. As part of a broader rebranding initiative, the gym was seeking to refresh its visual identity and widen its appeal across a more diverse demographic — attracting a broader cross-section of members including women and men of varying ages and backgrounds.

The client’s rebranding specification called for a carefully selected colour palette in a Pantone-referenced shade of grey, chosen to align with their new corporate identity. Following consultation with our coatings specialists, we confirmed an exact match using BS10A05 Goosewing Grey and Grey Green — a pairing that would deliver the refined, contemporary aesthetic the client envisioned whilst providing long-term protection to the substrate.

Pre-Contract Survey & Planning

Prior to mobilisation, our team conducted a thorough pre-contract site survey to fully assess the condition of the existing cladding and establish the full scope of works required. This structured assessment covered the following key areas:

• Detailed inspection of cladding panels and fixings to identify areas of corrosion, mechanical damage and coating failure
• Assessment of surface preparation requirements, including the extent of cleaning, priming and remedial repair works
• Calculation of coating quantities based on surface area measurements and the specified system
• Access planning to determine the most appropriate and safe method of working at height across all elevations
• Programme scheduling to minimise impact on day-to-day business operations

The findings of the survey informed our detailed project proposal and quotation, which was reviewed and approved by the client prior to works commencing.

Project Mobilisation

With the contract awarded and programme dates confirmed, D&D Coatings mobilised a specialist team of four technicians drawn from our Northern England Division, led by Project Director Gary Wright. The crew arrived on site in two fully-equipped D&D Coatings works vehicles, carrying all necessary tools, materials and personal protective equipment required for the project.

Surface Preparation

A rigorous programme of surface preparation was carried out before any coating was applied — a critical step in ensuring coating adhesion, longevity and the integrity of the manufacturer’s guarantee.

Access to the upper elevations was facilitated by the delivery and commissioning of an LGMG Rough Terrain Scissor Lift, supplied under a hire agreement with GTM Powered Access of Warrington. This provided our operatives with a safe, stable and efficient working platform throughout the project.

All cladding surfaces were subjected to a thorough high-pressure wash using a Bimson Petrol-Powered Pressure Washer, removing years of accumulated contamination, loose delaminated paint and organic growth. Following the cleaning phase, all fixtures, fittings and ancillary components — including CCTV installations and external luminaires — were carefully masked off to protect them from overspray during the application phase.

Cladding Repairs

Where the condition survey had identified areas of structural concern, targeted repair works were undertaken. Corroded and mechanically compromised fixings were replaced on a like-for-like basis. Cladding panels exhibiting dents or puncture damage were repaired using an appropriate body filler compound, which was then carefully profiled and rubbed back to match the original cladding geometry. A coat of specialist primer was applied to all repaired areas prior to the main coating works, ensuring a uniform, well-bonded substrate across the entire surface.

Coating Application

With all preparation and repair works complete, our team proceeded with the principal coating operation. As approved applicators for Rust-Oleum, D&D Coatings specified and applied the Rust-Oleum Noxyde Plus system — a high-performance elastomeric coating widely recognised for its exceptional durability and corrosion resistance on metal substrates.

Coating was applied by airless spray using a Graco Magnum ProX19, working systematically from the top of each elevation downwards and from left to right — a method that ensures consistent film build and eliminates the risk of surface contamination from overwork. The spray application method delivers a smooth, even finish that is both aesthetically superior and technically superior to brush or roller application at this scale.

The coating system was applied in two coats as follows:

1. First Coat: Rust-Oleum Noxyde Plus — Grey Green
2. Second Coat: Rust-Oleum Noxyde Plus — Goosewing Grey (BS10A05)

This two-coat system ensures a robust, consolidated film thickness in accordance with Rust-Oleum’s specification requirements and is a prerequisite for the issuance of their independently backed guarantee.

Project Challenges & Risk Management

One of the defining characteristics of this project was that the gym remained fully operational throughout the duration of the works — presenting a number of logistical and health and safety challenges that required careful management.

D&D Coatings implemented a comprehensive site management plan, incorporating appropriate hazard warning signage, pedestrian exclusion zones and public safety measures in compliance with current HSE guidance. This approach ensured that the safety of gym members, staff and visitors was maintained at all times, whilst keeping disruption to normal business operations to an absolute minimum.

Overspray management presented a particular challenge given the volume of vehicles parked adjacent to the building during peak hours. To mitigate this risk, all airless spray operations were programmed to take place during early morning and late afternoon periods, when car park occupancy was at its lowest. This proactive scheduling approach ensured that no complaints or incidents were recorded in relation to vehicle contamination throughout the project.

Project Outcome & Conclusion

The project was completed to programme and to the full satisfaction of the client. The finished result — a clean, uniform, professionally applied coating in the client’s specified colour scheme — has transformed the appearance of the building and materially enhanced its kerb appeal.

The client reported considerable satisfaction not only with the quality of the finished works, but with the professional conduct of the D&D Coatings team throughout. Our technicians were courteous, diligent and conscientious in their approach — reflecting the values we expect from every member of our workforce on every project we undertake.

The works were formally inspected and signed off by an authorised Rust-Oleum Representative, resulting in the issuance of a 10-Year Manufacturer’s Guarantee — providing the client with enduring peace of mind and tangible evidence of the quality and compliance of the installation.

Project Summary

Further reading;

Large Industrial Shed Unit Refurbishment in Essex
Cladding Coating at The Quadrant in Chester
Cladding Coating at Darland Sports Centre in Wrexham
Fading and chalking paint