Underlayment and Self-Leveller Re-Instate a Smooth and Tough Industrial Floor in UK Factory

Situation

This Yorkshire coatings factory needed to upgrade a former solvent store for modern manufacturing processes. This meant the old uneven and contaminated concrete was unsuitable for the new operation to be set-up in this area and it required the floor to be transformed into a level working surface which would be tough and durable as a production zone to withstand heavy loading.

Specialists from Sherwn-Williams worked with the client and the contractor to ensure that the requirement for a long lasting seamless functional industrial floor finish was met with a sound specification to deliver a floor meeting the designated performance criteria  within the allocated time frame for this project.

The Solution

The solution for this building involved several products from the Sherwin-Williams range of industrial floor coatings and screeds.  Following thorough preparation of the concrete base, the specification called for two initial primer coats. This is an essential part of the installation process to establish a sound and clean substrate which is suitable for a topping screed. Once primed, two applications of cementitious underlayment base screed were applied to cover the undulations and pitted areas of the substrate and to re-instate a sound level surface suitable for a resin topping. The underlayment is made with a factory pre-blended powder formulation being added to water. It is extremely durable and functions as a base screed in both industrial and commercial applications. This product can be applied by pump or by hand up to 50 mm in thickness and be topped with a wearing screed or overcoated with resin coatings in situations where an aesthetic finish is required and where protection is required from chemicals, oils and other liquids or if an improved slip resistant texture is required. 

Once the intermediate coats had cured over 24 hours, a pure epoxy resin primer was applied at around 300 gr/sqm and allowed to cure over night. This primer application enhances adhesion and ensures a completely sealed primed surface is created without any pinholes or air pockets. Finally an application of self-levelling epoxy resin is applied by rake and trowel as seamless coloured wearing surface at around 3mm thickness. This is the same system installed in areas such as laboratories and tv and film studios where a smooth shiny surface is required for modern equipment to be moved and operated with maximum efficiency. In this instance because the area was to be subjected to industrial traffic and footfall a fine anti-slip texture was required as the final wearing surface for this floor. This was achieved by applying a roller coat of colored high-build epoxy resin incorporating an aluminium oxide aggregate. The texture creates a profile which is proven to enhance anti-slip performance for footfall whilst also being cleanable within a normal industrial housekeeping regime to maintain health and safety and good aesthetic standards.

Outcome

The system delivered an outstandingly durable flooring substrate with a seamless finish to create modern working surface meeting health and safety standards and enhancing efficienct production in this building.