Case Study: High-Performance Resin Flooring for a Multi-Level Car Park

Updated: 4 days ago

4m Floors UK Case Study

4m Floors UK was tasked with delivering a durable and aesthetically pleasing resin flooring system for a high-traffic multi-level car park. The project involved preparing and repairing the concrete substrate, applying advanced resin systems, and finishing with precise linemarking. This case study highlights the meticulous process and cutting-edge techniques employed to ensure a high-quality, long-lasting result.

Preparation Phase: Shot Blasting

To ensure the car park’s concrete surface was in optimal condition for resin application, we began with shot blasting. This crucial preparation step involved the following:

Equipment Setup: Positioning and connecting power lines to the mains generator and dust collector (415V, 63A, 3-phase system).
Pre-Start Inspection: Visual checks of equipment functionality.
System Initialisation: Powering up the dust collector to build air pressure to 8 bar, checking compressor and motor functionality, and ensuring fault-free operation.
Surface Blasting: Using the 2-20DT machine with dead man’s handle for safety and regular checks of dust box residue levels.
Dust Disposal: Operators wore FFP3 masks and EN166-2001 safety eyewear while emptying dust boxes into designated skips.

Surface Refinement: Hand-Held Diamond Grinding

To complement the shot blasting, we employed hand-held diamond grinders for edge preparation and surface refinement:

Precision Grinding: Exposing the aggregate, minimizing grooving, and improving the surface finish.
Debris Removal: Comprehensive vacuuming to achieve a clean, dust-free substrate.

Concrete Repairs

After surface preparation, we addressed any imperfections to ensure a flawless base:

Ridge Grinding: Smoothing uneven surfaces.
Scratch Coating: Filling low areas with a mix of Aqualock Base A, Hardener B, and filler sand, followed by full blinding with 0.4-0.8mm quartz for improved adhesion.

Resin Application Systems

Deckshield ID (Lower Ground Floor - Cycle Stores)

Initial Layers: Shot blast and edge preparation followed by Aqualock Base application at 1kg/m².
Top Coats: Applying Deckshield Finish A and B with a squeegee and cross roller at 0.6kg/m² for a smooth, durable finish.

Decking Primer

Isopol SBR (1:5 dilution) @ 0.1 kg/m² per coat (if substrate is excessively porous)
Hydraseal DPM (Natural) @ 0.5 kg/m²
0.3–0.8 mm Dorsilit Natural Quartz @ 0.3 kg/m
(if substrate moisture content is above 75% RH)

Bodycoat + anti-slip aggregate

Deckshield SF @ 1.0–1.5 kg/m²
Dorsilit Natural Quartz 0.3–0.8 mm @ 2.5 kg/m²

Topcoats

Deckshield Finish @ 0.65 kg/m²

Note: If a UV light-stable and colourfast finish is required, apply an additional layer of Deckshield UV Topcoat.

Deckshield UV Topcoat @ 0.15 kg/m² (if required)

Peran STB Classic

Primer Application: Peran STC Primer with a light scatter of 7/8 coloured quartz.
Main Coating: Trowel application of Peran STC with coloured quartz at 7.4kg/m².
Top Coats: Peran TCW and Flowseal PU Matt for a sleek, matt finish.

Line Marking

Line marking was executed with precision to enhance the car park’s functionality:

Set Out: Measuring and taping 100mm wide lines.
Painting: Using QD Line marking Yellow applied with 4” rollers for clean, vibrant lines.

Results

The completed project showcases a seamless, robust resin flooring system capable of withstanding high traffic and environmental conditions. With its durable finish and clear linemarkings, the car park provides both safety and functionality for users.

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.