Factory Floor Transformation with High Build Polyurethane Coating
This project involved the complete refurbishment of a 900sqm factory floor using a High Build Polyurethane Coating. The extensive work was necessary due to the deteriorated condition of the previous flooring, which had undergone multiple repairs resulting in various layers of mismatched coatings.
Project Background
The factory floor had been subject to numerous patch repairs and coating applications over time, ultimately leading to a surface that was in extremely poor condition. The accumulated layers of old coatings created an uneven and unstable substrate, requiring a comprehensive solution to restore both functionality and appearance.
Surface Preparation
Diamond Grinding
To ensure a smooth and uniform surface, the entire floor was subjected to diamond grinding. This process effectively removed the old coatings and provided a consistent base for the new application.
Patch Repairs with High-Strength Epoxy Mortar
After grinding, any significant imperfections or voids were addressed using a high-strength epoxy mortar. These patch repairs were critical in creating a level and durable substrate capable of supporting the new coating.
Dust Removal and Vacuuming
Once the grinding and patch repairs were completed, the floor was thoroughly vacuumed to remove all dust and debris. This step was essential to ensure proper adhesion of the subsequent layers.
Priming and Final Surface Preparation
Application of Primer
A high-quality primer was applied to the prepared surface. This primer played a crucial role in promoting adhesion and sealing the substrate, ensuring the longevity of the final coating.
Blemish Re-Grinding and Repair
After the priming process, any remaining small blemishes or imperfections were re-ground and repaired. This meticulous attention to detail guaranteed a smooth, flawless finish.
High Build Polyurethane Coating Application
Final Coating Process
The final phase involved applying a High Build Polyurethane Coating. This coating was chosen for its durability, aesthetic appeal, and long life expectancy of well over 10 years. The coating was applied evenly across the entire surface to achieve a uniform, protective finish.
Incorporation of Anti-Slip Aggregate
To enhance safety, an anti-slip aggregate was integrated into the final coat. This not only provided a non-slip surface but also contributed to the overall durability and performance of the factory floor.
Benefits of Polyurethane Coatings
Polyurethane coatings are ideal for industrial applications due to their outstanding resilience and longevity. Key benefits include:
- Extended Life Expectancy: With proper preparation and application, these coatings can last well over 10 years.
- Superior Durability: Resistant to abrasion, chemical spills, and heavy traffic.
- Aesthetic Excellence: Provides a clean, modern finish that enhances the overall appearance of the facility.
- Safety Enhancements: The addition of anti-slip aggregates helps to reduce the risk of accidents.
Conclusion
This project highlights the importance of thorough surface preparation in achieving an amazing, long-lasting result. By diamond grinding the floor, executing precise patch repairs, and applying a high-quality primer, we created the perfect foundation for the High Build Polyurethane Coating. The final product not only restored the factory floor’s functionality but also provided a safe and visually appealing environment that is built to withstand the demands of industrial use.
