Case Study: Carbon Compounds Manufacturer

ACC Flooring was approached by a new client to put forward a resin flooring solution to a new portal frame building within their site in Darlington. The client manufactures and supplies carbon compound and timber wood products for aluminium, steel, chemical, rubber, railroad and utility industries for a worldwide market.

The client provided a comprehensive list of chemical products and their concentration levels which were likely to be stored in the newly constructed bund. After consulting with our resin manufacturer, a specification was proposed which would provide the client with an effective solution and give a life expectancy of 15 – 20 years.

A new concrete slab had been poured some weeks earlier to the 560 square metre area and had reached the required strength to receive a resin floor finish. The expansion joints were racked out and infilled with a resin rich, heavy duty polyurethane repair mortar which was allowed to cure as they were both too wide and too deep to be infilled with a flexible compound. The substrate was then mechanically prepared with diamond grinding equipment to provide a chemical key for the resin installation.

A heavy duty polyurethane screed @ 6mm was recommended due to the products seamless and slip resistant characteristics, in addition to very high chemical resistance properties. To provide heightened protection a UV stable top coat in a polyurethane chemical resistant coating in a gloss finish was applied. This product has the advantage of not picking up and holding any processed chemical waste pigments and is ideal for hostile environments.

2 coats of the polyurethane chemical resistant coating were also applied to the upstands around the perimeter of the bund @ 150mm high to provide enhanced containment and protection.

The expansion were then saw cut and infilled with a polyurethane modified epoxy expansion jointing compound designed specifically to provide both good chemical resistance and durability with a high degree of flexibility.

The installation was completed in 5 days and the client was delighted with the result.