Refurbishment of a production area floor

THE PROBLEM

As part of the refurbishment of the production area a new industrial flooring solution was required.


SOLUTION

Due to the requirement for good chemical resistance, slip resistance and resistance to steam cleaning we proposed the only viable solution – a 9mm polyurethane screed with coving to all upstands to create a seamless industrial resin floor.

Following the installation of a new concrete base by others, all surfaces were prepared by method of vacuum controlled scabbling and diamond grinding to provide a clean and profiled surface for the new industrial resin floor to adhere to.

Removing the surface laitance from new concrete is essential for excellent adhesion of any industrial flooring application, especially when elevated temperatures are present as this will serve to stress the bond between the resin floor and the concrete substrate.

Anchor rebates were cut at termination points and across the slab in order to prevent the new polyurethane screed ‘toasting’ during cure.

One of the key benefits of a polyurethane screed for industrial flooring applications is that they are resin rich through their full thickness. This means that if the floor is chipped or damaged, this will not allow water and chemicals to penetrate and attack the concrete beneath, which would serve to undermine the resin flooring.

Sherwin Williams RS69 was applied by method of pin rake and trowel to a thickness of 9mm to all horizontal surfaces. All vertical surfaces were rendered and coved using Sherwin Williams JT40 to prevent liquid ingress at this points.

To ensure a truly seamless industrial floor all coved and rendered areas were sealed using Sherwin Williams T100 polyurethane coating. We always undertake this as standard, something many other contractors omit to their detriment as the porous nature of unsealed coving will allow moisture and chemicals to penetrate over time.

Finally expansion joints were reflected and installed where present and along the drain perimeters. Installing expansion joints at drain edges is essential in industrial flooring applications such as this, as this differential expansion potential between the steel drains and the resin flooring can lead to cracking in these areas if expansion joints are not installed.

Further to this as polyurethane screeds cure, they shrink slightly causing the ‘toasting’ action as previously described. This means that there is a minute unsealed edge at the point most frequently exposed to water and chemicals, which over time will undermine the resin flooring.

Industrial Resin Flooring 10
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