Case Study: Chemical Plant

A long standing client of ACC Flooring asked if we could refurnish two external bunds whilst their plant was on shutdown.

The two bunds were side by side but both were in need of extensive work not only to the floor areas but also around the tanks and to the plinths. To one of the bunds, a crack had appeared in the floor which has run through the brickwork to the bund wall causing loss of containment. Due to the chemicals which were to be stored in the bunds a standard high build coating or chemical resistant coating would not give sufficient protection.

The existing failed coating to both bunds were uplifted, removed and disposed of. The floor areas, tanks and plinth surfaces were then prepared with vacuum controlled hand diamond grinders to remove any laitance. ACC Bulk, which is a resin rich heavy duty polyurethane repair mortar, was installed to any areas which required making good. This product is trowel applied and is ideal for use as an underlayment or infill. It can be applied at thicknesses of 10-60mm.

MasterSeal 7000CR flooring system was then applied to all surfaces. This system is a two component highly chemical resistant, crack bridging membrane based on Xolutec technology for waterproofing and protection of concrete structures in harsh conditions.

Xolutec is very low in volatile organic components (VOC), is quick and easy to apply with both spray and hand applications depending upon requirements. It cures rapidly even at low temperatures, reducing application time and minimising downtime. The technology is not sensitive to moisture and tolerates a wide variety of different site conditions, greatly expanding the application window and reducing the potential of delays and failures. Long maintenance cycles and lower life cycle costs significantly reduce total cost of ownership making this product ideal for chemical bunds.

The system consists of a primer coat and two top coats providing excellent chemical resistance, waterproofing, moisture tolerant, high water vapour permeability, high resistance to carbon dioxide diffusion, high tear, abrasion and impact resistance, high durability, flexibility and excellent adhesion properties.

The cracks to the floor surface and bund walls were saw cut and infilled with a flexible, chemically resistant mastic.

The client was delighted with the outcome and both bunds are now available for service.

ACC Flooring vast experience in the refurbishment of chemical bunds and providing bespoke solutions depending upon the chemical requirements.