Resin Flooring Installation
Resin Flooring Installation
Case Study
Resin Flooring Installation Case Study – Food Distribution Warehouse, Yorkshire.
Food Distribution Warehouse
Project Overview
JD Flooring recently completed a comprehensive resin flooring installation project for an expanding food sector distribution centre in East Yorkshire. The project encompassed a substantial floor area of 445 square metres within a newly acquired warehouse and storage facility where racking systems were already in position, presenting unique installation challenges.
Drawing upon our 24 years of experience in industrial resin flooring installation, our team approached this project with careful consideration of the specific requirements of the food sector. The existing client’s expansion plans necessitated a robust flooring solution that would address existing surface cracks while providing a durable wearing surface suitable for their distribution operations.
Assessment and Recommendation
Initial inspection revealed that 90% of the substrate was structurally sound, though specific areas required targeted attention. The most significant challenge was identified at the building’s upper section, where the removal of an office space had created noticeable height differences in the floor level. This assessment highlighted the need for a systematic approach to surface preparation and levelling.
Based on these findings, our technical team specified a comprehensive treatment plan. This included a heavy-duty grinding process, followed by edge grinding around the existing racking systems. The specification called for a bulk mortar application to create a seamless transition between the former office slab and the main floor area. The final system would comprise two coats of epoxy high-build coating, with the ultimate layer incorporating a light aggregate scatter to enhance slip resistance.
Preparation, Preparation, Preparation. It’s the Key
95% of all resin flooring installation failure is due to poor sub floor preparation
Preparation and Repair Details
The preparation phase began with the deployment of our triple-headed HTC heavy-duty grinder, ensuring thorough surface preparation across the main floor area. Our specialists followed this with meticulous hand-held grinding operations to properly prepare all building edges and racking feet, creating a uniform surface profile throughout the facility.
Once the grinding process exposed all structural details, our team identified and treated various cracks and day joints. We applied a flexible epoxy mortar to fill these voids, ensuring structural integrity and creating a sound foundation for the subsequent resin flooring installation. This careful attention to substrate preparation was crucial for achieving optimal adhesion and longevity of the final floor 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 Details
The resin flooring installation commenced with the application of a dark grey, hard-wearing epoxy coating across the entire 445-square-metre area. Our experienced installation team employed a squeegee application method, followed by back-rolling to ensure uniform coverage and optimal material distribution. This initial coating was allowed to cure overnight under controlled conditions.
The following day, we applied a second coat of the same high-performance epoxy system, this time incorporating a 0.3mm – 0.6mm aggregate to enhance slip resistance. This final layer was installed using identical application techniques to maintain consistency in finish and performance characteristics, creating a seamless, durable surface throughout the facility.
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 transformation of the distribution centre’s flooring system exceeded our client’s expectations, particularly in terms of functionality and aesthetic appeal. The new resin floor coating provided them with a safe, durable surface that perfectly aligned with their operational requirements while maintaining professional appearance standards essential for their food sector operations.
Our client specifically praised JD Flooring’s methodical approach to the project, highlighting our attention to detail and ability to deliver within the agreed timeframe. The successful completion of this resin flooring installation project further strengthens our portfolio in the food and distribution sector, demonstrating our capability to provide tailored flooring solutions that meet specific industry requirements.
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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