Resin Flooring Installation
Resin Flooring Installation
Case Study
Resin Flooring Installation Case Study – Large UK Furniture Manufacturer, Lancashire.
Large UK Furniture Manufacturer
Client Overview and Project Scope
As the approved contractor for a large UK furniture manufacturer, JD Flooring Limited recently undertook a significant industrial flooring project in Lancashire. This case study examines the comprehensive resin flooring solutions implemented across two key areas of the client’s facility: a 200m2 finishing area and a 980m2 goods-out area. The project showcases JD Flooring’s expertise in delivering tailored flooring solutions that meet stringent quality, safety, and operational requirements.
The finishing area, crucial for quality control, required a distinctive appearance. The goods-out area needed a complete refurbishment to comply with current health and safety standards. The client sought solutions that would minimise disruption to their operations whilst adhering to budgetary constraints and industry regulations.
Assessment and Recommendation
Following a thorough survey and assessment, JD Flooring proposed a bespoke solution for each area. For the finishing/QC area, the team recommended renewing the failed coating with a blue two-coat high-build system. This included the addition of a small aggregate to enhance slip resistance, complemented by 100mm safety yellow demarcation lines around the perimeter.
The goods-out area presented a more complex challenge due to its size and varied concrete surfaces installed over the years. JD Flooring suggested a shot-blasting preparation method to address the uneven surface, followed by a two-coat high-build epoxy resin system. This area also incorporated 100mm demarcation lines, spaced to accommodate vehicle widths.
A particular focus was placed on an 80m2 ramp with a 15-degree incline. To ensure maximum safety for forklift and pallet truck operations, the team proposed a specialised non-slip treatment. This involved applying the same two-coat system but fully blinding the first coat to significantly reduce the risk of skidding and slipping.
Preparation, Preparation, Preparation. It’s the Key
95% of all resin flooring installation failure is due to poor sub floor preparation
Preparation Phase
The project commenced with meticulous surface preparation. In the QC/finishing area, the team used a triple-headed grinder to remove the existing coating, employing hand-held grinders with PCD diamond attachments for stubborn areas. The goods-in area required a combination of hand-held grinders and shot-blasting with medium shot to prepare the larger surfaces effectively.
Once the substrate was exposed, it became evident that repairs were necessary. The team addressed this by scratching out epoxy resin with fillers for minor imperfections and using a repair mortar for deeper damage. This comprehensive preparation ensured an optimal surface for the new flooring system.
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
Following the preparation phase, the installation process began. In the blue finishing/QC area, the team applied two coats, incorporating the aggregate into the second coat and carefully back-rolling for even distribution. The goods-out area received its first coat via squeegee application to ensure even coverage over the variable concrete surface, followed by back-rolling. After an overnight cure, the second coat was applied using the same method, this time including the slip-resistant aggregate.
The ramp area required special attention due to its incline. Here, the team fully blinded the first coat with a coarser aggregate to maximise traction and safety for vehicles.
Resin Flooring Installation Case Study
Resin Flooring Installation Case Study
Resin Flooring Installation Case Study
Demarcation and Detailing
To complete the project, JD Flooring installed demarcation lines in both areas. In the blue finishing area, 100mm-wide safety yellow lines were applied around the perimeter using a heavy-duty epoxy line-marking system. The goods-out area received similar treatment, with 100mm safety yellow lines creating clearly defined bays for trucks and trailers. This not only enhanced safety but also gave the area a fresh, professional appearance.
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 project was executed in three phases, primarily over weekends, to minimise disruption to the client’s operations. JD Flooring’s ability to work within the client’s guidelines and operational constraints was crucial to the project’s success. Upon completion, the client expressed high satisfaction with the results, praising the improved aesthetics, enhanced safety features, and the professional execution of the work.
This case study demonstrates JD Flooring’s capability to deliver complex industrial flooring solutions that meet exacting standards of quality, safety, and functionality. By combining technical expertise with a deep understanding of client needs, JD Flooring continues to solidify its position as a leading provider of resin flooring solutions in the UK.
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
cheshire resin flooring installers
cheshire resin flooring installers
cheshire resin flooring installers
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