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Ultimate Hardwearing Flooring Solution

For Manufacturing Facility in Burnley

A Lancashire based global engineering manufacturer recently contacted Quest to seek a solution in refurbishing their existing floors. Previously Epoxy Coatings had been used, however over the years through daily usage and heavy traffic from the use of forklift and pallet trucks 24-7 the floors have been subject to damage.

Their existing flooring was expensive to maintain, and required a replacement coating every 5-7 years – So the client went to approved contractor Quest Industrial Flooring, Warrington looking for a practical and long-lasting surface which could withstand the daily rigours of the environment.

Flooring solutions

CDF Polished Concrete System from SIG Construction Accessories was recommended by the approved contractor Quest Industrial Flooring, as this system is not only hard wearing, but is also easy to maintain with a finish that will not delaminate due to the process of refining and polishing the existing concrete substrate.

Mark Jones, from Quest Industrial Flooring, explains the process they went through to ensure the client was happy with the CDF Solution. “Following an initial meeting in which their specifications were obtained, Quest carried out a site survey and recommended a 150m² site sample of grinding, dye application and polishing using the CDF system. After a successful three-month trial period of daily use, Quest was asked to carry out a further 1600m² of floor area throughout the factory.”

Expertise from the CDF team

Mark Jackson, Business Development Engineer, worked very closely with Mark Jones through all stages of the project to ensure the installation of the CDF system went smoothly and added – “The CDF team not only assisted with the initial sample but also provided training to the applicators, paid regular visits to site to oversee the installation and also follow-up visits after the installation. The team also organised a technical meeting presenting the maintenance procedure to the floor owner, cleaning contractor and Quest.”

Choosing the right products

Working together SIG and Quest jointly agreed on a range of products from the CDF system, which involved a composite of concrete densifiers, dyes, repair mortars and a stain protection system to meet the flooring demands of the client and project. Before the floor could be processed, preparation of the existing floor has to be carried out to ensure the best overall results. As part of this process SIG colour matched the existing flooring using Rapid Refloor repair products which were applied to any areas where damage had occurred. To harden the floor a 3DHS densifier was used, this provides a hardwearing surface which gives longevity and prevents dusting.

As part of the brief the client had requested a Grey floor to allow for demarcation of the isles, so Surelock Colour Dye was a perfect choice. This product impregnates and colours the cement, leaving no wear layer and ensuring there is no colour loss throughout the lifetime if the floor. The final step of the process was to add a guard system this was achieved by using the fully impregnating SR2 system being applied. This system guards against any spills and stains the floor may be subjected to as it gives a window of opportunity to clean any spillages.

When installing the CDF system, Quest used a variety of specialist machinery including the HTC 800 HDX, HTC 650HDX, HTC 10 & 15iAD Vacuum system, HTC 270 Edge machine and 25D vacuum system, all of which used HTC diamond grinding heads and floor cleaning machines to make sure the best installation and finish was achieved for the client.

All works were carried out in a ‘live environment’ with some areas being completed at weekends.