Kings Lynn, new factory floor

Due to the clients demanding process environment the most durable industrial flooring solution was required. We recommended the application of a 9mm polyurethane screed as the most suitable resin flooring solution.

Installing a new concrete slab

As part of our works package we were responsible for the breaking out and reinstatement of the defective concrete. When installing industrial flooring finishes it essential to ensure that the substrate to which you are applying to is sufficient. In this instance the condition of 90% of the concrete was so poor that the only option to ensure a long lasting resin floor was to remove the defective material.

The defective concrete was broken out using remote operated Brokk breakers and removed for off site recycling.

The new concrete was then installed incorporating both steel mesh and fibre reinforcement to minimise potential for shrinkage cracking.

Preparing the concrete and repairing cracks

To ensure optimal adhesion of the new industrial floor the concrete was thoroughly prepared using vacuum controlled diamond grinders and scarifiers to remove surface laitance from the new concrete.

The small section of floor which could not be removed due to access restrictions was repaired by dressing the cracks in the slab using a chaser prior to gravity feeding with Sika Sikadur 52 low viscosity epoxy resin to consolidate them.

Installing the new floor

Sikafloor Purcem 20 was installed at a thickness of 9mm, following the existing falls in the sub floor. Due to the resin rich nature of this material it could be applied directly to the concrete.

Polyurethane screeds are amongst the most durable forms of industrial flooring, due to the aggregate chippings contained within them. It is these aggregate chippings that give this type of resin flooring its slip resistance.

Creating a seamless finish

Due to the aggressive chemicals involved in the clients processes achieving a truly seamless finish was essential. All vertical surface surfaces were rendered using Sikafloor Purcem 29 and the same material used to install radius coving at the perimeters.

All coving and rendering were sealed using the same polyurethane resin in the form of Sikafloor Purcem 31. We deem this essential due to the more porous nature of the coving and rendering which would make these areas more susceptible to chemical ingress if not properly sealed – something other resin flooring contractors often omit to save money.

Polyurethane jointing compound

Finally all expansion joints were reflected and sealed using Sikaflex Pro 3 polyurethane jointing compound. This included the interface between the new resin floor and the stainless steel channel drain where movement could be expected due to the differing rates of expansion between the two materials.

The finished floor should provide a durable, long lasting industrial floor, that is a safe environment for our clients personnel to operate in.