The clients mild steel mezzanine floor was exhibiting signs of heavy corrosion as a result of severe chemical attack due to the process conducted. Failure to protect against this would lead to costly and disruptive replacement.
Due to the wide range and and varying concentrations of chemicals which the mezzanine floor is exposed to, an extremely chemical resistant resin flooring specification was required. For this reason we specified a glass flake reinforced vinyl ester protective coating manufactured by Chemco International for its outstanding chemical resistance to a broad range of aggressive chemicals. Furthermore the screened glass flake contained within give an extremely hard, durable and abrasion resistant finish.
Areas of the floor had a significant build up of scale and laminate corrosion. This was removed using a surface scaler/scarifier fitted with beam flails to impact the scale. Once the heaviest areas of corrosion/scale had been removed the entire floor was prepared to Swedish Standard SA 2.5 by method of vacuum enclosed track blaster by SPE International using an angular media to raise a surface profile. The benefits of this method of surface preparation are the dust free nature and the reduced exposure to noise and vibration. Finally the upstands/kick plates were prepared using Hilti Low Vibration needle guns, ensuring all laminate corrosion and scale was removed.
Once prepared all joints, welds and up stands received a stripe coat of Corroless EPF rust stabilising epoxy primer. A glass fibre reinforcing scrim was incorporated where necessary to give additional strength. Corroless EPF contains a mined pigment that converts corrosion present to inert magnetite, preventing further corrosion occurring. This allows the product to be applied to hand prepared or water jetted steel without the need for disruptive abrasive blasting. A radiused epoxy/quartz cove was installed to all upstands to aid maintenance and cleaning.
A coat of Corroless EPF rust stabilising epoxy primer was then applied to the entire floor to a dry film thickness of 250 microns. A 0.4mm – 0.8mm kiln dried quartz aggregate was broadcast into the uncured/wet resin to act as a barrier between the incompatible epoxy and vinyl ester protective coating systems. Furthermore this provided an excellent mechanical anchor for coating adhesion.
Once primed a coat of Chemco RB364 glass flake reinforced vinyl ester resin was applied by trowel in a light blue colour. Once cured this was followed by a second coat of Chemco RB364 in a contrasting dark blue to ensure full coverage. The final coat was back rolled to give a textured and slip resistant finish. The total system thickness of this chemical resistant resin floor was in excess of 3mm, giving an extremely durable wear course.