PSC Flooring recently completed a food grade flooring installation for PFDS BHAM Ltd at their new facility in West Bromwich, Birmingham. PFDS BHAM Ltd butcher and prepare Peri Peri Chicken for the supply of their restaurant and fast-food outlets.
The 920 square meter new facility was previously used for heavy industry and as such was undergoing a complete refurbishment.
The client was look for a heavy-duty food grade floor that would withstand constant washing down and cleaning. The floor would be subjected to wheeled stillages, pallet trucks and foot traffic.
At the site visit it was noted that the existing floor had previously been used for heavy industry and as such approximately 500 square meters had extensive residues of oil, dirt, swarf and grease as well as failed floor paint in some areas that would need to be removed and covered with an oil tolerant epoxy resin primer.
Also, the client intended to install a new drainage system that would result in approximately 50 square meters of newly laid concrete.
PSC recommended that to save the existing slab from having to be removed and relayed, a Nominal 12mm heavy duty cementitious base screed be laid to stabilise and reinforce the existing concrete slab. Followed by a nominal 6mm RT Polyurethane resin screed system, toed into the new drainage system.
In preparation for the 6mm RT Screed Food Grade Flooring the entire floor received a heavy shotblast to remove extensive residues of oil, dirt, swarf and grease on the floor.
Extensive repairs were made to damaged concrete, holes and trenches using polyurethane mortar compound, epoxy resin screed and cementitious base screed.
The failed floor paint was removed and the floor thoroughly cleaned and prepared using the captive doubled headed diamond grinding floor grinder and a handheld diamond grinding machine.
The floor was then vacuumed clean all residues and dust before a 1.5mm fibre mesh was added over existing metal rails 100m x 300mm and over all newly laid concrete areas, totalling circa 50 square metres.
6mm x 6mm Saw cuts were made to the perimeter of the intended RT polyurethane screed floor area, door thresholds, around drains and gullies and where necessary to toe in and anchor screed.
The heavily contaminated concrete received one coat of KDR Epoprime OT oil tolerant epoxy resin primer (circa 500 square meters).
The entire 920 sqm then was given a coat of KDR Epocoat MT moisture tolerant epoxy resin primer and heavy scatter a 0.6 to 1.2mm quartz aggregate.
A ramp was then formed, 100mm high x 2.5m x 1m, using Resdev Pumabulk heavy duty polyurethane mortar compound
The team machine pumped a nominal 12mm heavy duty fibre reinforced Weber 4320 cementitious base screed to the entire 920 square meter area. 90 tonnes in total the heavy-duty fibre reinforced cementitious base screed was installed to stabilise and reinforce the existing concrete slab.
920 square meters of nominal 6mm RT Polyurethane resin screed system in the clients chosen green colourway was hand laid to form a seamless food grade floor. RT Polyurethane resin screed is made up of a flint aggregate, water based polyurethane resin and a hardener.
The entire job took just 16 working days and the project was completed on time and within budget.
Well done team PSC Flooring 👍🏻💪🏻👷🏻♂️🦺
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