Dilapidated Warehouse Transformation

Works completed for one of the UK’s largest and most successful spare parts companies, supplying spares and consumables to large established companies, local councils, small companies and the general public. Since being established in 1971 they have expanded considerably on their site in Brownhills. They acquired a large unit next door to there main facility with a floor space of 28,000sq ft. IRL Group working with the delaps Contractor value engineered a flooring solution to cater for their needs within a specific budget.

The task was to convert a dilapidated, extremely uneven, contaminated concrete slab into a floor where automated guided vehicles could operate freely in a hygienic dust free environment. The project had to be a quick turnaround as the Client had an ever increasing order book to meet which meant they needed to expand quickly. The work was carried out in January with the external temperatures dropping below zero overnight this was not an easy task.

The concrete slab was thoroughly cleaned with a road sweeper. It was then heavily shot blasted to clean up the concrete and create a profile. All mechanical operations are vacuum assisted and are 99.9% dust free. All expansion joints were ripped out and infilled with epoxy resin mortar screed and marked with screws to identify their location. On completion of the preparation the floor was then coated with 2 coats of Flowcrete Hydraseal liquid DPM and a further coat of Flowprime that was fully broadcast with quartz sand. All excess quartz was then removed and Flowcrete Industrial Top pumped polymer screed was applied over the floor to a nominal thickness of 10mm.

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Expansion joints were then cut back through the floor. The floor was then sealed with 2 coats of Flowcrete SF41 high build epoxy resin incorporating aluminium oxide where the client required a slip resistant finish. All joints were then re-instated.

The job was completed within program and the client was extremely pleased with the end result. IRL have since worked with the delaps Contractor on numerous projects building a relationship which was born from this job.


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