East London is fast becoming one of the UK’s most sought-after hubs for data centre development, and Green Mountain’s new-build expansion at its LON-East campus in Romford is proof of that momentum.
Designed to meet the relentless demand for cloud computing, AI, and high-density workloads, the project will more than double the facility’s capacity to 14 MW by 2025, with a roadmap towards an eventual 30 MW.
For a development of this scale, every detail matters. From mechanical and electrical systems to the very floors beneath the racks of mission-critical servers, materials must perform flawlessly in environments where downtime is simply not an option.
This is where the partnership between Vebro Polymers and Loughton Contracts came into play, delivering a high-performance resin flooring solution that ticked every box for technical, environmental, and operational performance.
Delivering under pressure
Large-scale new-builds inevitably bring logistical challenges, and this project was no exception. Restricted delivery windows, coordination with multiple trades, and changing site conditions demanded flexibility and careful planning.
Environmental factors, including fluctuations in temperature and humidity, required constant monitoring to ensure resins cured correctly.
Despite these pressures, the flooring programme was completed within a four-month window, to the highest industrial standards, and without disruption to the overall construction schedule.
A benchmark for the industry
The successful delivery of the flooring package at Green Mountain’s LON-East expansion demonstrates the value of collaboration, technical expertise, and product innovation. With Loughton Contracts’ installation skill and Vebro Polymers’ integrated product offering, the project has set a new benchmark for resin flooring in data centres.
In a sector where reliability and resilience are everything, this project stands as a model of how flooring can underpin the critical infrastructure of the digital age.
Technical facts about Green Mountain’s LON-East expansion…
- Currently in operation
- 7 MW under construction, 7 MW to follow
- +16 MW build-to-suit expansion option
- First phase ready for service: Q1 2025
- Capacity: 14 MW
- Three data halls (plus a further three to follow)
- Total data hall area: 2773 m2 (plus 2773 m2 to follow)
- Concurrently maintainable infrastructure
- N+1 standby generators
- IT UPS distributed redundancy
- 2N electrical distribution
- Chilled water cooling using centralised adiabatic coolers and water-cooled chillers (N+1 redundancy)
Green at the core
Green Mountain is recognised internationally for its commitment to sustainable data centre operations, and this project was no different.
The resin systems supplied by Vebro Polymers are solvent-free, low-VOC, and designed for long service life, reducing lifecycle environmental impact. Seamless application minimised material waste, while robust certification supported the project’s drive towards BREEAM Excellent.
By aligning product selection with the client’s sustainability goals, the flooring installation contributed to a facility designed not only for today’s digital demands but also for tomorrow’s environmental standards.
Spotlight on the floor
Data centres present unique service criteria when it comes to flooring. Beyond the need for durability, systems must address static control, safety, hygiene, and resilience.
Electrostatic discharge (ESD) can cause irreparable damage to sensitive IT equipment, making a conductive flooring system essential in server halls. The floor must also withstand rolling loads from server racks, trolleys, and maintenance equipment, while remaining resistant to abrasion, impact, and chemical exposure.
Resin systems such as vebrostatic PU ESD SL (Conductive) offer further benefits that align with operator expectations: a seamless, joint-free surface that is easy to clean; impermeability to liquids to mitigate against spills or leaks; fire resistance to class Bfl-s1; and a solvent-free, low-odour formulation that promotes safe installation and long-term air quality. Added colour stability and the option of slip-resistant finishes ensure that performance does not come at the expense of aesthetics or safety.
Replacing the original specification
The project’s original flooring specification included a mix of competitor systems. However, through close consultation with the architect and main contractor TClarke, Loughton Contracts successfully introduced a full build-up solution from Vebro Polymers, supported by the required data sheets, certifications, and sustainability credentials.
This decision streamlined the process considerably. With all products coming from a single manufacturer, the client benefitted from a unified warranty and a simplified supply chain. For a project operating on a tight programme and with critical performance demands, this cohesive approach was a major advantage.
Technical precision on every layer
The installation required specialist expertise and exacting standards. Teams from Loughton Contracts, fully trained in Vebro Polymers systems, followed a meticulous programme of preparation, sequencing, and curing. Precision was especially critical in the conductive flooring areas, where copper earthing tape, conductive primers, and carbon-filled body coats had to be applied flawlessly.
To guarantee performance, electrical resistance readings were taken after each layer of the build-up. This ensured the floor was performing within the required conductive range and that the client could be confident in the system’s ability to protect sensitive equipment from harmful static discharge.
Inside the build-up
The installation covered approximately 8,500 m², though areas shifted slightly as the project evolved. Key stages included:
- Treating 8,000 m² of worn concrete slab with vebro EP DPM to act as both damp-proof membrane and bonding agent.
- Installing a v-Screed Max enhanced resin-bonded screed system at a depth of 40.0 mm before fully blinding with vebro Natural Quartz to provide a mechanical key.
- Applying vebroscreed Industrial at depths of 7.0 – 10.0 mm, forming the base for subsequent finishes.
- In the critical data halls, laying 5,425 m² of vebrostatic PU ESD SL (Conductive) flooring, finished in Pebble Grey (RAL 7032).
- Completing surrounding areas with 2,700 m² of vebrores EP HBC and vebrores EP HBC SR, offering chemical and abrasion resistance.
Meeting standards that matter
ANSI/ESD S20.20
Full title: ANSI/ESD S20.20 – Standard for the Development of an Electrostatic Discharge Control Program
Issued by: ESD Association (ESDA), USA
Purpose: Establishes requirements for creating and maintaining an ESD control program to protect sensitive electronic parts.
Key points: Specifies acceptable resistance ranges for flooring, footwear, garments, and work surfaces; defines grounding protocols; requires flooring in EPAs to measure <1.0 × 10⁹ ohms.
Why it matters: Many global tech giants especially in North America and Asia mandate ANSI/ESD S20.20 compliance across production and R&D spaces.
IEC 61340-5-1
Full title: IEC 61340-5-1 – Electrostatics – Protection of Electronic Devices from Electrostatic Phenomena
Issued by: International Electrotechnical Commission (IEC), worldwide
Purpose: Provides internationally harmonised guidelines for ESD-safe materials, EPA setup, and testing.
Key points: Aligns closely with ANSI/ESD S20.20, but with broader global recognition; includes detailed test methods for surface resistance, charge decay, and charge generation.
Why it matters: Often required by multinationals operating across Europe and beyond and frequently referenced in CE marking or ISO/IEC 17025 accreditation.
Conductive vs. dissipative: what’s the difference?
When it comes to electrostatic discharge (ESD) flooring, two main categories dominate the conversation: conductive and dissipative. While both are designed to protect sensitive electronics and equipment from harmful static build-up, their performance characteristics and applications differ.
Conductive flooring typically measures between 10⁴ and <10⁶ ohms in surface resistance. It provides a rapid, direct path for static electricity to discharge safely to ground. This makes it the material of choice for highly sensitive environments such as semiconductor fabrication plants, explosive processing areas, and precision electronics testing labs, where even the smallest spark can prove catastrophic.
Dissipative flooring, by contrast, sits between 10⁶ and <10⁹ ohms. It discharges static more slowly and in a controlled manner, reducing the risk of sparking while still protecting sensitive components. Dissipative systems are most commonly used in Electrostatic Protected Areas (EPAs), electronics assembly lines, and cleanrooms.
Regardless of the system, both require proper grounding – usually achieved via copper earthing tape beneath the surface – and must be tested to recognised international standards to verify compliance.
