The concrete factory floor in Norfolk was worn and dusting, with exposed aggregates and cracking visible across the surface. As part of the installation of new equipment, a durable and easy to clean epoxy resin flooring system was required to provide a hard-wearing industrial floor finish.
Factory Epoxy Resin Flooring Installation – Norfolk
THE PROBLEM
THE SOLUTION
We proposed several industrial resin flooring options to the client and the option they felt best met their requirements was a FERFA Type 3 resin flooring system – a high build epoxy floor coating.
To achieve proper adhesion to the concrete, all surfaces to be coated were first prepared using vacuum controlled diamond grinding. This process removes contaminants and surface laitance which would otherwise disrupt the bond of the epoxy flooring system to the concrete substrate.
Cracks in the slab were expressed using vacuum controlled diamond saws prior to consolidation by gravity feeding a low viscosity epoxy resin, helping to minimise the risk of reflective cracking in the finished resin flooring system.
Testing the moisture content of the slab
The moisture content of the concrete slab was tested and recorded to ensure conformance with the manufacturer’s recommendations and to ensure maximum adhesion of the epoxy resin flooring.
Climatic conditions during installation were also monitored and recorded, something many resin flooring contractors often overlook.
Any remaining minor defects were then filled with a twin component epoxy filler to further improve the aesthetics of the finished epoxy floor coating. Once cured, these areas were sanded flush.
Remmers Epoxy HB Colour was then applied in two coats to a nominal thickness of 1mm, forming the final high build epoxy resin flooring system.
The FERFA definition of a Type 3 resin floor coating begins at 300 microns (0.3mm), therefore this installation significantly exceeds the minimum specification. Applying the epoxy resin flooring at this increased thickness provides a more durable and long-lasting industrial floor coating.
Expansion joints were reflected in the new epoxy resin flooring using a vacuum controlled floor saw to prevent reflective cracking in the finished floor. These joints were then sealed using a flexible polyurethane jointing compound.
Emergency escape routes were then demarcated using a fast-curing Polyaspartic resin system, allowing these works to be completed within a single shift.
