4m Hygienic Resin Flooring
At 4m Floors UK, we recently completed a comprehensive resin flooring installation for a confectionery company, delivering an industrial-grade resin flooring system that meets both functional and aesthetic demands. This case study outlines the process, materials used, and benefits of installing a hygienic resin flooring solution in a factory setting, particularly for food manufacturing facilities.
Project Overview
Client: A major confectionery company
Location of Works: Factory Floor
Total Area: 1020m²
System Used: 2 x coats of water-based epoxy resin
Colours: Grey
The Challenge
For food and beverage industries like confectionery, maintaining hygienic standards on factory floors is non-negotiable. Floors are exposed to sugar, syrups, oils, and other ingredients, all of which can be detrimental if they infiltrate surface cracks. The client required a seamless, durable, and easy-to-clean flooring solution that would support their high standards of cleanliness and safety while enduring heavy foot and machinery traffic.
Given the high level of hygiene and durability required, resin flooring was identified as the best solution. Resin flooring offers a smooth, impervious surface that can withstand chemicals, thermal shock, and frequent cleaning, making it ideal for the food production environment.
Preparation Phase
A critical element to ensuring the longevity and performance of hygienic resin flooring is surface preparation. Our team at 4m Floors UK took several preparatory steps to ensure that the factory’s floor was ready for the application of the resin system.
Equipment and Tools
We supplied all necessary tools and machinery for the project, following the Provision and Use of Work Equipment Regulations 1998 (PUWER). All equipment, whether owned or hired, underwent strict PAT testing and certification before being brought on site. Our site managers ensured that any damaged or faulty equipment was quarantined and returned for maintenance.
Surface Preparation
Hand Held Diamond Grinder: We began by preparing the floor area using a 110-volt handheld diamond grinder equipped with a dust suppression unit. The goal was to expose the concrete aggregate while minimising grooving. This step is crucial as it increases adhesion for the resin system.
Dust and Debris Removal: Once the floor was ground, all dust and debris were thoroughly removed using a vacuum to ensure a clean surface ready for the next stage.
Joint Repairs
Proper joint repair is essential to create a seamless floor finish. We vacuumed out all joints and filled them with Thixo and Resin before allowing the material to cure. This process ensures no gaps are left that could lead to dirt or moisture accumulation, which could compromise the hygiene of the floor over time.
Applying the Hygienic Resin Flooring System
After the surface preparation, the application of the hygienic resin flooring system could begin. We opted for a two-coat system using Epocoat WD, a water-based epoxy resin known for its excellent adhesion, durability, and chemical resistance.
Step 1: HTC Diamond Grinder Preparation
Before applying the resin, we conducted another round of surface preparation using an HTC diamond grinder with a dust control unit. This helped ensure that the floor was as smooth as possible, with no surface defects that could interfere with the application of the resin.
Step 2: First Coat of Epocoat WD
We mixed the Epocoat WD using a 110-volt slow-speed mixing drill, combining Hardener B with Base A for two minutes to achieve a uniform mixture. This was applied to the prepared floor using a squeegee at a rate of 0.2kg/m² to ensure an even and full coating. The first coat was then left to cure.
Step 3: Floor Repairs
Once the first coat had cured, our team inspected the floor for any minor cracks or holes. These were filled using P38 Body Filler, ensuring a completely smooth surface for the final coat.
Step 4: Second Coat of Epocoat WD
We repeated the mixing process for the second coat of Epocoat WD, again ensuring uniform consistency by mixing for two minutes. The second coat was also applied with a squeegee at 0.2kg/m². After this application, the floor was left to cure fully, resulting in a durable, long-lasting, and hygienic surface.
Results and Benefits
The new resin flooring system we installed provided the confectionery company with numerous benefits:
Hygienic and Easy to Clean: The seamless nature of the hygienic resin flooring ensures that there are no joints or cracks where bacteria can accumulate. The epoxy surface is resistant to the chemicals and solvents commonly used in food production cleaning processes.
Durable and Hard-Wearing: Resin floors are known for their strength and ability to withstand both heavy foot traffic and machinery movement. This durability is critical for busy food production areas, ensuring a long-lasting flooring solution.
Chemical and Thermal Resistance: Food production environments are exposed to varying temperatures and occasional chemical spills. The water-based epoxy system we used offers excellent resistance to these challenges, reducing the risk of floor damage over time.
Slip-Resistant: For safety reasons, it was essential to ensure that the flooring was slip-resistant. The slight texture created during the diamond grinding process enhances the floor’s grip, reducing the risk of slips and accidents.
Conclusion
The resin flooring solution provided by 4m Floors UK has transformed the factory floor for this confectionery company. With its seamless, durable, and hygienic properties, the new floor not only meets but exceeds the strict health and safety standards required for food production.
This project underscores the importance of high-quality hygienic resin flooring in industries where cleanliness, durability, and safety are paramount. Resin flooring systems are ideal for sectors such as food and beverage production, providing a cost-effective and long-lasting solution.
If you're looking for resin flooring solutions for your business, contact 4m Floors UK today to learn more about how we can help.
4m Resin Flooring Contractors for Over 30 Years
For 30 years, 4m Floors UK has been at the forefront of delivering specialised resin flooring solutions that combine durability, aesthetic appeal, and cost-efficiency. Whether you need a robust industrial floor, a decorative car park surface, or a sanitary environment, our expert team is equipped to meet your needs.
At 4m Floors UK, we take pride in being a trusted name in resin flooring contractors, offering a comprehensive range of services tailored to large projects. From terrazzo installations to floor signage, manufacturing flooring, car park solutions, and food and beverage flooring, our expertise and versatility enable us to meet the unique needs of various industries. Contact us today to discuss your project requirements and experience the difference our quality resin flooring solutions can make.
If you have any questions please do get in touch at sales@4mfloors.co.uk or alternatively give us a call on - 01782 576650
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