Resin Flooring Installation
Resin Flooring Installation
Case Study
Resin Flooring Installation Case Study – Engineering Company, Warrington.
Engineering Company
Project Overview
An engineering company based in Warrington recently relocated to new premises, requiring their 165m2 manufacturing floor space to be brought up to health and safety standards. The client also had a company requirement for all operational areas to achieve aesthetic standards and ensure easy cleaning and maintenance of the flooring.
The existing floor had been coated repeatedly, resulting in a 1mm thick coating in some places. JD Flooring assessed the area and presented a proposal to the client, focusing on thorough preparation.
What were the main challenges faced by the client in their new premises?
Assessment and Recommendation
After surveying the floor, JD Flooring suggested using a double-headed diamond tip grinder to remove the multiple layers of existing epoxy coating. We then recommended installing a 2-pack epoxy high build system with a fine aggregate to improve slip resistance and overall health and safety.
During the removal process, it became evident that the previous epoxy flooring system had been installed without proper subfloor preparation. As a result, the removal was easier than anticipated, with around 50-70Kg of the previous flooring being removed.
How did improper subfloor preparation by the previous occupants affect the longevity of their flooring solution?
Improper subfloor preparation by the previous occupants significantly affected the longevity of their flooring solution in several ways:
Poor adhesion: Without proper subfloor preparation, the epoxy flooring system did not adhere correctly to the substrate. This lack of adhesion likely led to the flooring peeling, chipping, or delaminating prematurely, necessitating frequent repairs or recoating. How does the constant need for repairs impact the cost-effectiveness of a flooring solution?
Uneven surface: Failing to address imperfections in the subfloor before installation resulted in an uneven surface, which may have caused the epoxy coating to wear unevenly. High spots or low spots in the substrate can lead to accelerated wear in certain areas, reducing the overall lifespan of the flooring. What safety hazards can an uneven flooring surface present in a manufacturing environment?
Moisture issues: If the previous occupants did not assess and address potential moisture issues in the subfloor, it could have led to the failure of the epoxy coating. Moisture can seep through the substrate, causing the flooring to bubble, warp, or delaminate. How can moisture-related problems contribute to the deterioration of a resin flooring system?
Inadequate cleaning: Improper cleaning of the subfloor before installation can result in contaminants being trapped beneath the epoxy coating. These contaminants can interfere with the bonding process and lead to the premature failure of the flooring system. Why is a thorough cleaning of the subfloor essential for achieving a long-lasting flooring solution?
The previous occupants’ solution of simply adding another layer of epoxy coating without addressing the underlying issues was a short-term fix that ultimately exacerbated the problem and likely incurred higher costs in the long run.
Preparation, Preparation, Preparation. It’s the Key
95% of all resin flooring installation failure is due to poor sub floor preparation
Preparation and Repairs
The preparation process involved using the suggested grinders, as well as flatbed grinders for edges and around columns. The “goods-in” area was also prepared.
Our preparation phase was conducted with exceptional care to ensure the floor’s surface was evenly treated. This equipment, known for its efficiency, was vital for smoothing the large area swiftly.
After completing the preparation, several holes and cracks in the substrate were identified and repaired using a suitable repair mortar.
Frequently Asked Question
Why is thorough preparation and repair work crucial for the success of a resin flooring installation?
Thorough preparation and repair work is crucial for the success of a resin flooring installation for several reasons:
Adhesion: Proper surface preparation ensures that the resin flooring system adheres properly to the substrate. If the surface is not adequately prepared, the new flooring may not bond correctly, leading to premature failure, peeling, or delamination. How does poor adhesion affect the longevity of a resin flooring system?
Durability: Repairing cracks, holes, and other imperfections in the substrate before installing the resin flooring helps to create a solid, stable foundation. If these issues are not addressed, they can lead to further deterioration of the substrate and cause damage to the new flooring over time. What role does a stable foundation play in the overall durability of the flooring system?
Aesthetics: A well-prepared and repaired substrate ensures a smooth, even surface for the resin flooring installation. This results in a more attractive and professional-looking finished product. Imperfections in the substrate can telegraph through the new flooring, compromising the aesthetic appeal. How can a poorly prepared substrate impact the visual appearance of the finished resin flooring?
Cost-effectiveness: Investing time and effort in thorough preparation and repair work can save money in the long run. By addressing issues with the substrate before installation, you can avoid costly repairs or replacements down the line due to premature flooring failure. Why is it more cost-effective to invest in proper preparation and repair work upfront?
Thorough preparation and repair work are essential for achieving a long-lasting, durable, and visually appealing resin flooring installation. Neglecting these crucial steps can lead to a host of problems that compromise the quality and longevity of the flooring system.
Installation Process
Once all preparation and repair work were completed, the areas were thoroughly cleaned to ensure a dust-free environment before installation commenced. JD Flooring installed the first coat of epoxy high build using a squeegee method and back rolled it to produce a smooth finish. This first coat was left overnight to cure.
The following day, the cracks and repair areas we attended to again to ensure the final layer would result in a perfect finish. The same installation method was repeated, this time scattering a 0.4mm-0.8mm aggregate into the surface and back-rolling to an even finish. The result was a perfect finish for the environment and the new working area.
Resin Flooring Installation Case Study
Resin Flooring Installation Case Study
Resin Flooring Installation Case Study
Resin Flooring Installation Case Study
Resin Flooring Type Used - Resin High Build Coating
Exceptional Thickness for Added Durability
Resin High Build Coating is an ideal flooring solution for demanding environments that require added protection and durability. This innovative coating is designed to provide a thicker layer than traditional flooring options, ensuring maximum resistance to wear and tear, even in the most challenging spaces.
Long-Lasting Protection
Resin High Build Coating is engineered to withstand heavy foot traffic, machinery, and impact. Its exceptional thickness guarantees long-lasting protection against daily wear, making it the perfect choice for industrial facilities, warehouses, and other high-traffic areas. Invest in a flooring solution that can stand up to the test of time.
Customisable Aesthetic Appeal
You can enhance the appearance of your space with the versatile design options offered by our Resin High Build. Choose from a variety of colours and textures to create a visually appealing environment that aligns with your brand and style preferences. Enjoy the perfect combination of functionality and aesthetic appeal in one innovative flooring solution.
Resin High Build Coating Characteristics
Feature | Details |
|---|---|
| Application | Applied in two or more coats, solvent free |
| Intended Use | Medium Duty use |
| Thickness | Up to 1000 microns |
| UV Resistance | 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 |
JD Flooring Guarantee
- Manufacturer Backed Warranties
- 23 years Project Bank
- Free Surveys and Advice
- Industry Approved Contractors
- Quality Assurance ISO9001
- Quality Assurance ISO14001
Client Satisfaction and Feedback
The client expressed his delight at the work carried out and the new finish. As a direct result of the quality of work completed by JD Flooring, the client has confirmed that he wishes to appoint us again to install resin flooring in the rest of the building later this year.
Feedback from other JD Flooring Clients
Request a Quote
With over 2 decades of experience as Resin Flooring Installers, JD Flooring is ideally placed to deal with your requirements, from your initial enquiry, product selection and project planning, to the installation, quality control checks, after sales service, repairs and maintenance.
Contact our experts to arrange a free, no obligation, consultation and site visit, allowing us to provide you with a project cost, timeframe and available start dates. Pricing starts at only £4.00 per square metre – inclusive of preparation, labour & materials.
Cheshire resin flooring installers, Resin Flooring Installation Case Study
Resin Flooring Installation Case Study, Cheshire resin flooring installers
Cheshire resin flooring installers, Resin Flooring Installation Case Study
cheshire resin flooring installers
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