The old laminating floor
The old floor
The old floor
The failed resin floor being stripped
Clean and prepared concrete
The finished floor
The finished floor
The finished floor
The finished floor
Introduction
Condale Plastics required a complete replacement of a failed resin floor at their East Grinstead facility in East Sussex. The existing 550 m² floor had laminated and lifted, making it unsuitable for continued use and creating the need for a durable, professionally installed replacement. Following investigations and the success of an Elgood trial patch, Elgood Industrial Flooring was appointed to remove the failed floor, carry out remedial repairs and install a new 2 mm Britdura 2000 solvent free epoxy floor in Light Grey with a fine slip resistant finish.
Background
The existing floor at Condale Plastics had been laid by another contractor and had failed, with the resin laminating and lifting away from the substrate. This left the site with a floor that no longer provided the durability, appearance or reliability expected in an industrial working environment.
Condale Plastics needed a replacement floor that would not only resolve the existing failure but also offer better long-term performance and easier day-to-day housekeeping. The client wanted a finish that would be hard-wearing and practical, while still allowing routine sweeping and cleaning without difficulty.
As British manufacturers and installers with more than 125 years of industrial flooring experience, Elgood Industrial Flooring was able to assess the failure, prove the proposed solution through a trial patch and then deliver the full replacement system using its own in-house team.
The Challenge
The project needed to address several clear requirements:
- Remove and replace 550 m² of failed resin flooring that had laminated and lifted
- Resolve problems caused by a previously installed floor laid by another contractor
- Identify and repair defective areas in the substrate that had been overlooked in the past
- Provide a durable industrial floor with a fine slip resistant finish that would not inhibit sweeping and housekeeping
- Complete the strip-out and replacement within a tight programme leading into the Christmas shutdown
The Solution
Elgood Industrial Flooring specified and installed a complete industrial flooring replacement system for Condale Plastics in East Grinstead.
Key elements of the solution included:
- Trial patch and investigation
Before the main works began, Elgood carried out investigations and installed a successful trial patch. This gave Condale Plastics the confidence to proceed with full replacement of the failed floor. - Removal of the failed resin floor
The failed flooring was removed over a single weekend. This allowed the defective system to be stripped out quickly and prepared the site for the new installation programme. - Preparation of the concrete substrate
Preparation included the use of an electric Multi Stripping Machine to lift the old floor. Dust free shot-blasting was then used to remove existing paint, clean the concrete and provide a strong physical key for the new epoxy system. Diamond grinding was used to prepare the edges and detailed areas. - Remedial repairs to defective areas
Elgood anticipated that remedial work would be required and found a number of defective areas that had been overlooked previously. These were excavated and repaired using an industrial strength smoothing screed, creating a more reliable substrate for the new flooring. - Britdura 2000 solvent free epoxy flow coat
Condale Plastics selected Elgood Industrial Flooring’s Britdura 2000 solvent free epoxy flow coat at a nominal thickness of 2 mm. This system was chosen to provide a hard-wearing industrial floor with a smooth, professional appearance. - Light Grey finish with fine slip resistance
The floor was finished in Light Grey and included a fine slip resistant texture. This gives the floor enough purchase underfoot while still allowing effective sweeping and general housekeeping.
The new floor was installed over five days leading up to the Christmas shutdown, allowing the project to be completed within a tightly managed programme.
Outcome
The completed industrial flooring installation provided Condale Plastics with a durable and reliable replacement floor in East Grinstead:
- A new 550 m² Britdura 2000 solvent free epoxy industrial floor
- Full removal of a failed laminated resin system laid by another contractor
- Repaired and strengthened defective areas in the substrate using industrial strength smoothing screed
- A Light Grey finish with fine slip resistance that supports everyday safety and easy housekeeping
- A project completed to programme, with strip-out over one weekend and installation over five days leading into the Christmas shutdown
By combining careful investigation, thorough preparation, targeted repairs and a proven Britdura 2000 epoxy flooring system, Elgood Industrial Flooring delivered a long-lasting industrial floor that resolved a failed installation and gave Condale Plastics a more dependable surface for the future.
