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Zircon Flooring refurbished Rolls Royce's 14000m2 vehicle production site using Sikafloor seamless, rapid-apply, slip resistant resin system without interruption to the car assembly plant.
The client required a surface with a detailed, high-quality finish. With durability and low-maintenance among its many other benefits, Sikafloor’s high-quality resin system proved ideal for the project. A flooring installation of such magnitude presented a number of challenges which had to be overcome by Zircon to meet the client’s strict 18-day deadline and ensure minimal disruption to the plant’s day-to-day running. It meant Sikafloor had to live-up to its easy-to-apply, high-performance billing to ensure the testing timetable of works was adhered to. To overcome random static charges which can affect sensitive electrical components and wreak havoc on a busy car production line, Sikafloor®-262AS, a two-part electrostatically conductive textured epoxy coating, was used for the floor’s refurbishment. With good chemical and mechanical resistance, this slip-resistant flooring system is designed to deliver the ultimate in static control and has an excellent reputation in industries where there is sensitive electronic equipment such as hospitals, TV studios and pharmaceutical manufacturing plants. As well as its excellent technical and aesthetic properties, the Sikafloor system has a ‘refreshability’ option to extend its lifecycle, thus providing a cost-effective, sustainable alternative to the installation of a complete new floor. For the Rolls Royce project, Zircon prepared the concrete substrate by mechanically shot-blasting and diamond-grinding the surface using dust-controlled methods to ensure plant operations elsewhere were not affected. Sikafloor®-161 primer was then applied, followed by Sikafloor®-263 SL multipurpose binder . Once levels were checked and grinded as required, Sikafloor® Earthing Kit, a conductor system comprising copper earthing tapes and points, was installed. A layer of Sikafloor®-220W anti-static primer was added, and once cured, the flooring was finished with Sikafloor®-262AS to a nominal thickness of 2mm. With work starting in December and continuing during the festive period, 7,000m2 of existing floor had to be ground-off before relaying could start, with Zircon’s teams working throughout the night to ensure the project’s completion in readiness for the New Year and the site’s return to full operation. To further minimalise disruption, Sika and Zircon employed a detailed project management programme. This was drawn-up with full client agreement in order for work to be scheduled around the plant’s production needs. This effective project management meant the intensive refurbishment was completed to the given deadline and the client’s full satisfaction. The superb new floor stands as a smart, seamless, showcase for the versatility and durability of Sika’s exemplary flooring range.
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