Manufacturing & Warehousing

Global engineering company, VTL Group has a stylish yet tough solution for its new building in Huddersfield, West Yorkshire from local companies Ultrasyntec and Resdev.

Utilising products from Resdev Ltd, Ultrasyntec worked within a tight five day timescale to achieve a colour co-ordinated flooring system over a combined area of more than 3000m2. The initial application of Resdev’s Pumaprime DPM, epoxy damp proof membrane, was followed by two coats of Pumashield, a medium viscosity high build epoxy coating with excellent abrasion and chemical resistance qualities. The building’s walkways were coated in Pumashield in Midnight Blue with the rest of the floor in Resdev’s Mid Blue shade. In addition to this, VTL needed to install hard wearing anti-slip matting to the entrance areas immediately in front of the large roller shutter doors but, instead of having to source these elsewhere, Ultrasyntec offered an innovative alternative with the development of a bespoke ‘sandwich system’ designed to withstand the rigours of a heavy duty environment. This consisted of the installation of Resdev’s Pumadur SL, seamless polyurethane flowable resin flooring system, into which a scatter of quartz aggregate was applied until the system was fully blinded. This was then allowed to cure before a final application of Pumashield in Midnight Blue to finish the ‘sandwich’ application. Lee Sunderland of Ultrasyntec added ‘the overall appearance of the floor was of paramount importance to the customer, with a specific request for no visible preparation or grinding marks to the finished installation. We were able to meet this requirement despite the limited time window for completion before other trades were scheduled to be on site and our dedication has paid off as we are now ready to complete the next phase at VTL’.

The iconic brand that has adorned the feet of supermodels, leading actresses, high society celebrities, and royal families – Gina Shoes decided to relocate to larger premises to provide both production and design facilities to fulfil the growing demand for their extraordinary footwear and accessories.

A former clothing warehouse totalling over 3,000sqm that was chosen for the new Gina Shoes factory, offers a vast production and warehouse facility, as well as a design studio and client viewing area, making it the perfect location to grow this superb brand. However, before Gina could relocate to the new premises, most areas of the facility had to undergo major renovation to ensure the interiors corresponded with the professional identity of the business. Following consultations with specialist resin flooring company, National Flooring, it became apparent that not one, but a variety of solutions were needed to meet the different requirements within the building. Gina also made it very clear that the end result had to be synonymous with everything that the company stands for – uncompromising quality, elegance, and style. To fulfil all Gina’s requirements, National Flooring chose the specialist range of Degafloor MMA resin flooring systems, which deliver outstanding quality, practicality, and exceptional flexibility in terms of aesthetics.

Boxford Ltd is the leading manufacturer of training machine tools in the UK and when they required 3250 sq metres of hard working flooring for their brand new factory in Elland they turned to local company, Ultrasyntec Ltd

As leading global suppliers of CNC equipment and CAD/CAM systems for schools, colleges and universities, Boxford were determined to build a centre of excellence for fabrication, component machining, CNC control, electronics and software under one roof with clearly marked bays and traffic areas specific to their manufacturing needs and to contribute to the cohesive development. Using Pumashield medium viscosity epoxy resin coating, manufactured by Resdev Limited, UltraSyntec laid out the bay marking and walkways to co-exist with the innovative movement sensitive lighting system and over head automated cranes. In defined and contrasting red, green and grey sections, the coating was applied on top of Resdev’s Pumaprime DPM, solvent-free liquid applied damp proof membrane and residual moisture suppressant. The seamless finish is cost effective and offers excellent abrasion and chemical resistance. It was completed by UltraSyntec’s own trained and skilled workforce to ensure a continued high quality of service from specification, through to application and after care.

A US biotech business invested £5m in a new European headquarters in Manchester. The building footprint expanded from 11,000 sq ft. to 60,000 sq ft. and required a durable hygienic, easy to clean, seamless floor.

For the expansion of this biotech headquarters, the change of use of each of the buildings required the flooring to be brought up to a suitable standard by installing durable, easy to clean, seamless resin flooring. Air tight electrical doors were fitted therefore the floor levels had to be at the correct datum lines. It was essential that the fittings were precise to avoid any potential areas where air movement control and contamination could be a problem. A clean room environment was crucial due to the nature of the research. The project was short listed for the FeRFA Large Project of the Year FeRFA awards 2012.

ACC Flooring helped Scotts Miracle Grow in a major refurbishment project including a visitor route through the works, to allow school visitors to see how the company cared about the local area and planet.

As an American horticultural company, Scott’s Miracle Grow, has definite views on environmental responsibility and were impressed with ACC’s obvious commitment to sustainability. The project required new floors throughout the factory to include safety walkways, storage areas, anti-slip areas etc. The current building had years of product on them and there was no idea of any footprint of where people should and should not go. The work required careful planning as the need for the product is very seasonal and weather dependent. This meant access could be given to carry out the works only during quieter periods.

Zenith Pola Flooring Services provided a durable high build epoxy coating system and new demarcation lines to the tired flooring at the Leicestershire HQ of engineering company Burgess AP.

Burgess AP has been engineering quality metal ceilings for over 60 years and have clients in both the UK and abroad. The engineering headquarters are based in Hinckley, Leicestershire. Zenith Pola Flooring Services Ltd were asked to survey and specify a flooring solution for their factory floor. The substrate itself was in a fairly poor condition and the overall appearance of the floor needed improving. An economic, durable finish was specified in the form of 2 coats of ZenRite Coat Industrial, a durable high-build epoxy coating system. Yellow demarcation lines were then applied to denote walkways and safe zones using ZenRite Line Marking Paint.

The IRL Group has completed the refurbishment of a medical fill area at BOC Ltd’s Wolverhampton facility. The work was completed within four days so as not to disrupt production at the plant.

BOC Ltd is the largest supplier of gases, associated equipment and related services in the United Kingdom. They serve a range of industries including healthcare, food and drink, refrigerant and other speciality uses. Their medical fill facility in Wolverhampton required refurbishment earlier this year and the IRL Group was able to complete all the works over an extremely tight programme of four days to minimise disruption to production. The existing coating to the 1500 sqm area had to be removed by shot blasting following which isolated repairs we made using epoxy screed. A FeRFA type 6 epoxy broadcast system to a depth of 4mm was laid and sealed with two coats of high build solvent free epoxy coating and all movement joints were reinstated.

Central Flooring Services has installed 350m2 of FeRFA type 5 anti-static flooring for a new assembly workshop for a local electronics company to keep their expensive and sensitive electronic equipment safe.

Central Flooring Services has just completed 350m2 of FeRFA type 5 anti-static flooring for a new assembly workshop for a local electronics company. The specification called for the grinding of the existing concrete followed by the installation of a new anti-static resin flooring system with high durability and aesthetics. Once the floor had been fully ground and vacuumed all cracks and chips were repaired with an epoxy repair mortar and primed with Peran STC. Earthing points were then installed with copper strips along the floor surface at pre measured points and channelled under any expansion points so the connection would not be broken once the expansion joints were re-instated. A layer of Peran ESD conductive primer was applied and then the 2mm Peran ESD conductive resin flooring system, with the expansion joints being cut and sealed. Once the installation was complete the floor was tested for conductivity by the manufacturer. The specification was paramount to the client who is using very expensive and sensitive electronic equipment and he was very pleased with the advice, installation service and overall result he got from Central Flooring Services.

The oil contaminated floors of a food package manufacturing facility receives a complete refurbishment with a durable heavy duty resin screed to meet food industry standards.

East Coast Flooring were contacted by a leading packaging company for the food industry to survey their variable flooring issues. After establishing their requirements, ECF carried out a test area for evaluation and the specification was accepted. The works required vigorous preparation via removal of existing asphalt by mechanical breakers and planning, followed by captive shot blasting to prepare the surface fully for application of the flooring. Two coats of RSL’s Dampshield or Oil Tolerant Primer were applied followed by the application of 6mm Resuscreed 43 Epoxy screed (FeRFA type 6). The screed was then sealed using two coats of Resucoat HB High Build Epoxy Resin coating (FeRFA Type 3). Finally all existing joints were saw cut and re-filled. The products chosen gave protection against any residual moisture in the substrate and to cope with oil contamination from the machines and production of materials. The heavy duty screed system would provide the client with a tough and long term flooring solution which the client would find easy to clean and above all offer a hygienice surface. The work was completed in five days whilst the factory was still in operation. As can be seen from the before and after pictures below floor is barely recognisable from its pre-refurbished state.