McDaid and Sika keep the coffee flowing for Costa

Costa Coffee’s highest-producing roasting plant in Basildon required a high-quality flooring to cover a 5,000m2 area. The system needed to be durable, sustainable with thermal capabilities of up to 70°C.

Main contractors, Volker Fitzpatrick, selected McDaid Screeding specifically for this project as the company’s specialist expertise in screeding and resin-based projects. The £36million Costa Coffee plant, which opens in 2017, is designed to manufacture 45,000 tonnes of ground coffee per year. Sikafloor®- PurCem® HS21, a high-gloss, water-based, polyurethane, met the brief as it offers a thermal and scratch resistant, high-aesthetic finish in areas of extreme hygiene, such as food preparation. The resin was installed in two phases, each phase being approximately 50% of the total flooring area. Firstly, Sikafloor®-161, a two-part epoxy primer was applied. Once cured, it was followed by 4mm of Sikafloor®-210 Purcem, a resin scratch coat, and 4mm of Sikafloor®- 210 Purcem screed. Sikafloor®-310 Purcem provided a polyurethane, high-gloss finish. In addition, existing concrete joints were raked out and filled with Sikaflex® PRO-3, a one-part, moisture-curing, self-levelling elastic joint sealant. The project encapsulates how a manufacturer’s innovation in developing a sustainable solution can be interpreted by a specialist contractor to suit a client’s needs and be fit for purpose for a major building project. The excellent working relationship between the specialist contractor and manufacturer was vital in this case, with Sika providing relevant technical information and application support throughout the extremely challenging installation.