Case Study: Food Manufacturer – West Yorkshire

ACC Flooring were contacted in August 2025 by the new client who had purchased new premises close to it’s existing site in West Yorkshire, the new premises had originally been used to manufacture cleaning products and was in need of a full refurbishment and refit to turn it into a new food processing facility for one of their many lines.

As one of the largest independent wholesale distributors of Asian Foods established over 50 years ago this allowed for the companies continuous growth and development. The area that required a new resin flooring system was approx. 700m2, which would be split into areas of various use.

Phase 1 was to install the new drainage system required, Blucher UK visited site along with ACC Flooring to discuss drainage options with the client and once drawings were agreed a custom built drainage system was to be installed.

• 2 sections of drainage channel, 1 of 13lm and 1 of 26lm along with 2 sumps of 1.2m x 1.2m each were to be fitted.
• Floor cutting works were required to create and enable the installation of the drainage channels, several tons of spoil and waste were mechanically removed from site.
• A polymer modified sand and cement screed was then installed to anchor in the new drainage system and left to cure.
• The newly installed drainage system was then protected by the client, whilst other works took place on site prior to ACC Floorings return to install the resin flooring all as per the clients programme of works.

ACC Flooring returned to site, preparation of the floor was then carried out by way of enclosed shotblasting and hand held diamond grinding as required. A sand and cement polymer modified screed was then laid to falls to allow the flow of water or product into the drains to avoid any standing liquid in the area. Over 60 Tonnes of screed was installed over a 6 day period and then left to cure.

The benefits of a polymer modified screed are that it can be installed externally as well as internally and can be applied down to a low of 10mm thickness, is water resistant and has a good tensile strength, the polymer additive allows installation of resin systems on top in as little as 3 days, whereas a traditional sand and cement screeds would take weeks to cure, adding significant time onto the project programme.

Once cured preparation of the newly installed screed was carried by way of handheld diamond grinding; to remove any laitance and provide a clean substrate to receive the selected resin systems, all preparation equipment is vacuum attached to encapsulate dust.

Pumadur HF a heavy duty polyurethane screed in Dark Grey at a nominal thickness of 6mm was then installed, which included toeing in to maintain key levels. A natural slip resistant profile in the product helps to provide a safe environment in both wet and dry conditions, which makes it ideal for use in Food Processing, Food and Drink Preparation, Breweries, Commercial Kitchens, Chemical and Pharmaceutical Production and Storage Areas.

Polyurethane Screeds have a high durability, impact abrasion and good chemical resistance. Installed at a nominal 6mm thickness they are suitable for freezer temperatures down to -25⁰C. And installed at 9mm thickness down to -40⁰C, providing it is of a good quality concrete which is essential to install resin systems onto.

Heavy Duty Polyurethane Screeds have an anticipated lifespan of approx. 10 – 12 years, with good housekeeping in place and are HACCP Certified.

In total 147 linear metres of Coving was installed as required at 100mm high capped with a birds beak trim and formed using a Pumadur WR a seamless polyurethane mortar for vertical surfaces in Dark Grey and sealed with Pumagrout a solvent free Grout Seal coat in Dark Grey.

Expansion Joints were reinstated as required using Pumexpand PU a polyurethane jointing compound designed to provide good chemical resistance and durability along with a degree of flexibility.

Due to excavation works needed a huge amount of waste was produced, ACC Floorings recycling commitment meant 100% of waste produced during this project was recycled, whilst providing a fully sustainable resin flooring which will provide many years of service.