Major Floor Repairs to Production Area

Client Requirements

In the High Care production area of a leading ice cream producer, extensive floor repairs and alterations were necessary to maintain operations at the highest standard. Zenith Contract Services was entrusted with this critical task, ensuring that the work was executed efficiently and with minimal disruption to the client’s workflow.

Overview of Works

• Phase 1: Preparation: The first step involved breaking out the existing ceramic tiles and subfloor. Using heavy breakers, our skilled team carefully saw-cut the area to create neat and defined edges, leaving a rebate approximately 70mm deep to expose the structural concrete beneath. This meticulous preparation laid the groundwork for the subsequent phases of the project.
• Phase 2: Polymer Underlay Application: Next, we applied a troweled polymer underlay using Ardex A38. This advanced material allowed us to reinstate the floor to approximately 6mm below its original level, providing a stable base for the final layer. After allowing for adequate curing time, we proceeded to the next phase.
• Phase 3: Polyurethane Screed: The area was then topped with Pumadur HF polyurethane screed, meticulously matched to the existing profiles in a Buff colour. This careful selection ensured seamless integration with the surrounding flooring, creating a cohesive and aesthetically pleasing appearance.

Finally, we introduced a joint at the perimeter where the new and existing floors meet, filling it with Pumexpand jointing compound. This detail not only provided a perfect match but also ensured a seamless transition between surfaces, enhancing both functionality and safety.