Project Details

Bayset were tasked with upgrading an existing industrial warehouse floor. The initial flooring was poorly designed and after 3 years had become too rough to drive on. The total floor area of 233 square metres (warehouse runway) is utilised to house industrial materials and is subjected to constant heavy mechanical traffic. A quick turnaround was required so business could continue as soon as possible. The project was undertaken over the Easter long weekend with the warehouse closing on Thursday and reopening on Tuesday.

Methodology

Surface preparation: the surface of the concrete was prepared by a combination of shot blasting and diamond grinding. All loose material, surface laitance, contaminants and or curing compounds were completely removed.

Skim coat: Due to the CSP left from the shot blasting the surface was then skimmed with Hychem E300SL blended with select silica sand. Due to the depth of the voids the skim coat was applied three times in order for the product to level. Once dry the surface was then lightly abraded with a terrazzo grinder to remove any surface imperfections.

First pigmented coat: the Hychem Supafloor resin and hardener were mixed together in the correct ratios using a mechanical variable speed helical mixer for 3 minutes. No solvent was added. The mixed product was then poured onto the floor and spread by roller and back rolled to a uniform finish. The coverage rates were 0.5 - 1ltr / m². Once dry the surface was then lightly abraded with a terrazzo grinder to remove any surface imperfections.

Final pigmented coat: Prior to blending resin and hardener and to improve the anti-slip the resin was filled with 12% by weight CA60# white aluminium oxide and then stirred. Then Hychem SF12FG resin and hardener were mixed together in the correct ratios using a mechanical variable speed helical mixer for 1 minute. Then add 10% solvent to assist with application and mix for a further 2 minutes. The mixed product was then poured onto the floor and spread by roller and back rolled to a uniform finish. The coverage was approximately 5m² / litre.

Hychem NS - joints recut and repaired: the existing floor joints were resaw cut to approximately 10mm x 10mm and then filled with Hychem Hyflex NS pigmented a similar colour as the floor. Some floor joints were cut to a 50mm width due to the amount of expansion occurring.

Result & Testimonial

"The quick turnaround time meant business could continue as soon as possible."

Bayset were able to provide an extremely hard wearing, tough and durable surface with high mechanical strength. The completed flooring offers excellent resistance to chemicals and its smooth, high gloss finish makes it easy to clean.