System Installed
-
PMMA Quartz Resin Flooring System
Flexible Resin Joint Detailing
Checker Plate Bonding Primer
Two Protective Seal Coats
Curb Repair and Colour Matching
Gemstone Industrial Flooring was appointed to refurbish two production areas within a busy bakery manufacturing facility.
The works were carried out close to live production, meaning hygiene, safety and installation speed were key considerations.
The existing flooring included worn concrete and a heavily corroded checker plate loading area between two rooms. The original transition ramp was extremely steep, which caused difficulties for forklifts transporting pallets of product between areas.
Our objective was to create a durable, hygienic flooring solution while improving the transition between the two areas and keeping disruption to the client’s production schedule to an absolute minimum.
The Challenge
The project presented several technical challenges:
• Corroded checker plate that required specialist bonding preparation
• A steep transition ramp which created operational issues for forklifts
• Limited working space inside the production environment
• The need for a rapid cure flooring system so production could resume quickly
Because the works were carried out within a food production environment, materials also needed to be safe to install close to operational areas.
PMMA resin systems were chosen due to their fast curing time, durability and hygienic finish.
Our Solution
The existing concrete floor was mechanically prepared before priming to ensure a strong bond with the new flooring system.
To address the transition issue between the two rooms, a 4 metre ramp was constructed from the existing checker plate loading area down to the concrete floor. This created a much smoother transition for forklift traffic.
A specialist primer with an additive designed to bond to steel substrates was used to achieve a chemical bond onto the checker plate surface.
Once primed, a flexible resin layer was installed across the metal plate and joints to accommodate movement before installing the main flooring system.
A yellow quartz PMMA resin flooring system was then installed across both areas and finished with two protective seal coats to provide a durable, slip-resistant and hygienic surface suitable for food production environments.
Damaged curbing within the adjoining room was also repaired and colour matched to the new flooring system.
The Result
Despite the complexity of installing the new ramp and preparing the checker plate substrate, the entire project was completed in just two days.
One of the key benefits of the PMMA flooring system is its rapid curing time.
The floor was ready for use within one hour of completion, allowing the client to move equipment back into place and resume production immediately.
The finished floor provides a durable, hygienic and slip-resistant surface designed to withstand heavy forklift traffic and the demanding conditions of a food production environment.
The client was extremely pleased with the finished result and the minimal disruption caused during installation.
Need a Resin Flooring Upgrade in a Live Food Environment?
We specialise in fast-curing, heavy-duty industrial resin flooring for:
-
Food processing facilities
-
Meat production plants
-
Commercial kitchens
-
Cold storage
-
Industrial manufacturing sites
