THE PROBLEM
The loading shovels at the waste recycling centre had eroded the original concrete slab to such a point that the shovels were then prone to catching on the floor and abruptly halting presenting a safety hazard.
The plant has incoming loads daily which means that any industrial flooring repairs have to be undertaken in an extremely narrow window.
SOLUTION
We propose the application of one of the most durable forms of Industrial Resin Flooring available – Master Builders Solutions Ucrete IF. This is a polyurethane screed which is already amongst the toughest forms of Industrial Flooring further reinforced with the addition of iron filings to give additional abrasion resistance.
Because of the severe erosion of the concrete it was necessary to first conduct extensive slab repairs and a concrete overlay.
Initially the perimeter of the area of the slab to be repaired was saw cut and broken out using robotic demolition to the required minimum depth. This was then transitioned using robotic breakers and surface planers.
The entire slab received a heavy profile by method of scabbling in order to provide a profile for the repair materials to adhere to. Prior to installing the new concrete the slab was primed using an SBR slurry to promote adhesion and the concrete laid into this whilst still wet.
Given the programme constraints an extremely fast curing concrete mix was supplied by Hanson Cement in the form of their Fast Track material. A design was employed which would have the compressive and cohesive strength to be prepared the very next day. For additional crack resistance this material was also fibre reinforced.
To minimise the risk of fracturing in the new concrete we prepared the concrete by method of vacuum contained track blasting the next day to ensure any surface laitance was removed and ensuring excellent adhesion of the new industrial resin flooring.
Polyurethane cement materials are perfect for application onto recently installed concrete as they have few limitations with regard to the moisture content of the substate. Particularly important on industrial resin flooring applications such as this where time is constrained.
By contrast most epoxy flooring systems would require multiple primer layers to tolerate such high moisture concentrations in the concrete, adding days to the programme.
All areas to be treated were primed using Master Builders Solutions Ucrete Primer FS. This fast curing primer can be applied in overlayed within the same day.
Master Builders Solutions Ucrete IF was applied by trowel to a target thickness of 12mm for additional wear resistance. Existing expansion joints in the concrete slab were reflected in the new resin flooring finish as per best resin flooring practice.
All works were completed within the allocated week and the floor was returned to service the following week, supported by the fast curing nature of Ucrete materials.
