THE PROBLEM
The tiled floor was leaking and allowing water ingress into the high voltage switch room below. Our client required a waterproofing solution and flooring finish that could withstand the rigors of a heavy duty industrial environment that would be exposed to aggressive chemicals and steam cleaning.
SOLUTION
We propose the removal of the existing tiles and sub screed, waterproofing of the structural slab, installation of improved stainless steel drainage and finally heavy duty industrial flooring finishes in the form of a 9mm polyurethane screed.
For this project for the combination of both waterproofing and resin flooring we partnered with Master Builders Solutions as they were able to provide a complete materials solution, supplying both the polyurea waterproofing materials and the resin flooring polyurethane screeds.
Initially the tiles and screed were removed using vibration damped breakers to expose the structural slab. Once exposed all surfaces to be waterproofed were prepared by method of vacuum controlled diamond grinding to ensure excellent adhesion of the new polyurea waterproofing membrane.
As part of our standard quality assurance climatic conditions and substate moisture content were tested and recorded throughout the application process to ensure suitability inline with the waterproofing manufacturers recommendations.
Waterproofing with Polyurea
All surfaces to be waterproofed with polyurea with double primed using Master Builders Solutions P770. This primer is extremely moisture tolerant and by double priming fully sealed the surface prior to the application of the polyurea membrane.
Following cure of the primer Master Builders Solutions M689 pure polyurea waterproofing membrane was spray applied to a thickness of 2mm. This highly elastic polyurea material can elongate in excess of 400% before breaking, making it the perfect sealing solution for over this critical part of the factory.
Testing the Polyurea membrane
The polyurea membrane was tested for integrity using a DC holiday spark tester as part of our standard quality assurance and repairs made using the same material. Because of the extremely quick gel time of polyurea waterproofing materials (Sub 10 seconds) this could be conducted almost instantly and then repairs made within the same shift. This is actually essential when applying polyurea materials as they have a very narrow recoating window which must be closely adhered to in order to achieve good inter coat adhesion.
Falls to drains were then installed using polymer modified concrete, with the drain being installed as a separate slab in order to create greater movement potential due to the exposure of the floor to rapid changes in temperature if the adjoining tanks have to be rapidly drained.
Preparing the the polymer concrete
The new polymer concrete was prepared by method of diamond grinding prior to the application of Master Builders Solutions Ucrete Primer FS. Being based on the same polyurethane cement technology as the subsequent polyurethane screed it is highly damp tolerant and vapor permeable, making it ideal for application to new screeds with high residual moisture contents.
Master Builders Ucrete UD200 was applied to a thickness of 9mm – the necessary thickness to give the new resin floor the necessary temperature resistance for steam cleaning and the heavy industrial flooring requirements.
All upstands were rendered using Master Builders Solutions Ucrete RG in order to achieve a seamless finish. Finally expansion joints were reflected in the new resin flooring finish using a vacuum controlled floor saw prior to sealing using a high temperature polyurethane jointing compound.
By combining a polyurea waterproofing membrane with a new slab and polyurethane screed we were able to provide maximum waterproofing with high durability – all from one company.
