THE PROBLEM
As part of the conversion of the old printing works to a food production factory a solution was required to repair the badly damaged walls constructed from insulated panels and the installation of a suitable resin flooring solution.
SOLUTION
We proposed the application of our proven Corroflex Elastomer to the walls and a 6mm polyurethane screed to the factory floor. Corroflex Elastomer will adhere to nearly all substrates, including foil faced insulation panels. Further this due to its highly elastomeric properties it can tolerate any flexing that may be present in structures such as this without cracking, flaking or peeling.
Initially all surfaces were vacuumed clean and any peeling foil facing cut back. To ensure the correct climatic conditions for coating application heating was introduced and the climatic conditions tested and recorded.
The first coat of Corroflex Elastomer was applied by method of airless spray at a practical consumption of 0.5Kg. Following cure defects in the insulated panels and hole sin the block work were all filled using a flexible filler. This is another benefit of the membrane like properties of Corroflex Elastomer, in that it can encapsulate and tolerate all manner of substrates.
A second coat of Corroflex Elastomer was applied by method of airless spray in the same manner as the first. Finally to give an easier to clean finish Corroflex Sheen Finish was applied by method of airless spray. This hygienic finish also contains a biocide that kills mould, spores and bacteria that come into contact with the coatings surface.
As part of the new resin flooring stainless steel drainage was required to be installed as commonly seen in food factory resin flooring. The area to be broken out was isolated using a floor saw, prior to breaking out using an 8 Ton machine. All material removed was taken away by grab lorry for crushing and recycling.
The new stainless steel drains and sump were set and bedded in prior to pouring a fast curing C40 concrete design which was allowed to cure for 2 weeks.
In preparation for the application of the new polyurethane screed all existing coatings were removed by method of captive track blasting, with the edges being prepared by method of vacuum controlled diamond grinding. Track blasting where possible is widely recognized as one of the best forms of resin flooring surface preparation.
Following preparation as part of our standard quality assurance the moisture content of the slab was tested and recorded along with the ambient climatic conditions.
The polyurethane screed was then installed to a thickness of 6mm using pin rakes and trowels. Polyurethane screeds have become the de facto resin flooring for food factories for the following reasons;
- Extremely durable
- Slip resistant
- Resin rich through their full thickness, making them impermeable even if scratched or gauged.
A 6mm screed was installed as opposed to the 9mm that would be required if steam cleaning was to be undertaken in the food factory, which in this instance it was not.
Following installation of the polyurethane screed expansion joints were reflected and sealed using a polyurethane jointing compound as per best resin flooring practice.
