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Industrial Resin Flooring to Loading Pads, East Anglia

THE PROBLEM

The four concrete product loading pads had lost the majority of the previously applied Industrial Resin Flooring, meaning that corrosive liquids from the product stored on the bads had caused degradation of the concrete.

The consequence of this was that our client was losing a percentage of their product that they had paid for due to abrasion from the course concrete. The works were located over 4 sites throughout East Anglia, with over 10,000m2 of Industrial Resin Flooring required and over 3,500m of expansion joints to remove and reinstate.

THE SOLUTION

Initially as part of developing the correct Industrial Resin Flooring solution for our client we proposed the installation of sample areas, applying several different systems from Remmers. After scabbling the concrete to remove exposed aggregates and prepare the concrete different materials applied at different thicknesses were applied, with a selection of aggregate dressings.

Following the installation of the sample areas the client evaluated them for both product loss and slip resistance with the heavy shovel loaders that operate on the loading pads 24/7 when in operation.

The industrial resin flooring specification that was selected was Remmers PUR Grip 100 with a 0.9mm – 1.2mm Bauxite dressing.

Because of the size of this resin flooring project and the hardness of the concrete despite the erosion preparing the concrete using conventional resin flooring preparation equipment was not viable for cost effective.

For this reason we appointed specialist subcontractor Power Plane to scabble the concrete using equipment more conventionally used in highways applications.

As a result of water used for dust suppression during the scabbling works a cement slurry had formed over all surfaces where the new industrial resin flooring was to be installed. This had to be removed in order to ensure proper adhesion of the new resin flooring.

This was undertaken by means of high pressure washing, directing the slurry towards the central drainage for treatment via the clients on site water treatment plants.

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Any aggregates recovered were used on site for repairing access roads.

An unusual challenge that we had to contend with on one of the four sites was the presence of large number of geese, which would contaminate the freshly prepared and cleaned concrete. This had to be repeatedly removed prior to the application of the resin flooring.

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As part of our standard resin flooring quality assurance the climatic conditions with regard to temperature, relative humidity and dew point were closely monitored and recorded to ensure compliance with the manufacturers recommendations.

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Remmers PUR Grip 100 was then applied by squeegee and roller to a thickness of 2mm and blinded to saturation with bauxite to provide the durable high frication resin flooring required and identified by our sample areas.

Our teams were able to install approximately 1000m2 of this system per shift, having to work closely as a team on site to ensure that the aggregates were scattered very quickly into the wet resin due to the high temperatures.

Because of the size of this project recovering the excess aggregates manually was not a possibility. Thinking big we used a sweeper attachment on the Telehandler to recover excess aggregate.

This was cleaned through a screening hopper and re-bagged for reuse, thus minimising product usage and waste.

Expansion joints to be reinstated were primed using Remmers Underwater primer applied by spray for expedience, followed by sealing using Remmers pourable twin component flexible polyurethane jointing compound.

When installing heavy duty industrial flooring such as this in demanding industrial applications such as this it is essential that expansion joints are reflected and sealed in the new resin flooring.

This prevents reflective cracking in the new resin flooring finishes as would be the case if they were overcoated and also serves to protect the joint arises.