An renowned International Oil Export Company, located in the heart of the West Midlands, approached JD Flooring Ltd for a significant update on their resin screed flooring system. Five years on from the original resin screed installation, the vast expanse of 1,650m² required a fresh coat and updated safety features to enhance operational efficiency and safety.
The project involved reapplying a high-performance two-coat resin flooring system across various sections of the facility, integrating new demarcation zones to streamline workflow and improve onsite safety. A pivotal aspect of this installation was the introduction of a larger aggregate in the second coat, aimed at reducing slip hazards and fork lift skids, while ensuring the floor remained easy to clean and maintain.
After conducting a comprehensive site survey, we assessed the floor’s condition and how it met operational needs. We concluded that a two layer high build coating system we previously installed still suited the environment perfectly, thanks to its durability and ability to withstand heavy industrial use.
The survey also highlighted areas that needed repairs and demarcation to maintain the facility’s high safety standards. These improvements will bolster the facility’s safety protocols, guiding foot and machinery traffic more effectively, and delineating specific zones clearly without compromising the floor’s aesthetic appeal or functionality. This approach was designed to ensure the safety measures integrated smoothly with the existing workspace environment, enhancing both visual appeal and operational safety.
Our preparation phase was conducted with exceptional care, employing dual planetary double-headed grinders to ensure the floor’s surface was evenly treated. This equipment, known for its efficiency, was vital for smoothing the large area swiftly.
For detailed work, particularly around edges and columns where precision is crucial, we utilised flatbed grinders equipped with Polycrystalline Diamond (PCD) attachments.
Upon identifying sections of the screed that were damaged, our team deployed kango breakers to meticulously remove these compromised areas. This step was essential to prevent future issues and ensure the longevity of the new flooring. Following this removal, we applied a robust polyurethane mortar to fill in any gaps and repair the substrate. This material was chosen for its durability and ability to create a strong, cohesive surface, ready for the new coating.
This detailed preparation work laid a solid foundation for the new resin flooring installation. By addressing each area with the appropriate tools and materials, we ensured that the substrate was not only repaired but also enhanced, ready to receive the new coating layers with optimal adhesion and a smooth finish.
Post-preparation and repairs, the first layer of epoxy coating was evenly spread using a squeegee, then carefully back rolled to achieve a flawless base. After a curing period of 24 hours, we applied the second coat, this time incorporating aggregates of 1mm-2mm at critical points like ramps and doorways, and a slightly finer 0.7mm-1.2mm aggregate for the rest of the floor. Doorways received a striking safety red topcoat, designed to catch the eye of fork truck operators and drivers, enhancing navigational safety.
Upon the successful application and curing of the resin flooring solution, our team embarked on the final stage of the project. The tape used to edge the walkways and hatchings was replaced with durable, 100mm yellow safety lines.
The bright yellow lines clearly demarcated the placement of new pallet location boxes, the pedestrian pathways from operational zones and clearly defined loading lanes, providing a high-visibility guide that ensures safe navigation through the busy operational areas. This careful application of safety markings encapsulates our commitment to delivering both aesthetic and functional flooring solutions.
The feedback from our client post-installation was overwhelmingly positive. They commended the upgrade, particularly appreciating the introduction of a larger aggregate which has proven effective in maintaining a safe and clean environment. The improvements have not only met but exceeded client expectations, reinforcing JD Flooring Ltd’s reputation for delivering tailored, high-quality flooring solutions that enhance workplace safety and operational efficiency.
A solvent free epoxy coating applied in two or more coats, building a film thickness of up to 1,000 microns. It is specified for medium duty use where the requirement is a clean, hard wearing surface over sound concrete.
Aggregate is scattered between coats where a slip resistant finish is needed. Anticipated life is 5 to 7 years in light use and 2 to 4 years under moderate use.
| Application | Applied in two or more coats, solvent free |
|---|---|
| Intended Use | Medium duty use |
| Thickness | Up to 1000 microns |
| Chemicals | Some resistance to chemical spillage |
| Slip Resistance | Aggregate can be added to achieve a slip resistant finish |
| Anticipated Life | Light use 5-7 years / Moderate use 2-4 years |
StockportHigh Build Coating
West MidlandsHigh Build Coating
WarringtonHigh Build Coating
West MidlandsHigh Build Coating
WalesHigh Build Coating
CheshireHigh Build Coating
LeicesterFloor Seal
LeicesterHigh Build Coating
WalesHigh Build Coating
Tell us how the area is reached, what happens in it and how long it can be closed. We attend, test the substrate, and put a written specification and a fixed price in front of you at no cost.
