Case Study: Pre-Construction Epoxy Floor Planning, Budgeting, Specification & Installation for Staub Manufacturing, NY
Background: Pre-Construction Planning
Innovative high-tech manufacturer was planning a fast-track building schedule for its new 70,000 square foot state of the art facility. Nuflorz was referred by a long-time customer.
Nuflorz was asked to offer several resinous floor coating systems specifically for the company’s different operation’s needs. This was during the planning stages of the project 12 months prior to breaking ground.
In order to meet this request, Nuflorz met with the owner, Nuflorz studied the existing facilities, it’s day to day operations, and process and its current floor systems shortfalls. The long-term future processes and potential changes to these were also part of the discussions.
Two floor systems were selected, one for the production floor, ProRez epoxy Self level system, with a Prothane topcoat. The second system was a ProKrete SLB for the loading dock and warehouse area.
Production Floor
The production floor received a ProShield Epoxy Self level system. The first layer was a MB primer designed to be installed over newly poured. The Matrix layer was a UV formula White epoxy self-level – with a light broadcast of black flake. The system was topped with a final gloss topcoat of Prothane with pro texture.
Loading Dock / Warehouse Flooring
The Heavy traffic and loading dock areas received a ProKrete SLB with Prothane topcoat. This system is designed to address the harsh abuse of loading dock areas with heavy traffic.
The installation was completed by the NUFLORZ INC team, specializing in industrial floor coatings for 30 years. This project was completed ahead of schedule by working first, second and third shifts, NUFLORZ met the facilities highest standards.
Project Details
- Scope: Design, Specify and install a floor coating system for Staub new facility. ,
- Timeline: Scheduled for completion as soon as the new construction environment permitted.
- Results:
Issues Encountered
- New Concrete, fast track schedule.
- Manage a new product that is added to concrete for strength, large braided concrete fibers.
- Substrate moving after the installation.
Corrective Actions Taken
- New Concrete, fast track schedule. Utilized ProRez MB to tolerate a newly poured slab and its moisture content.
- Manage a new product that is added to concrete for strength. large braided concrete fibers. As the floor preparation began, the shotblasting uncovered all of the braided fibers that were added to the concrete for strength. Addressing these unforeseen issues was important to deliver a quality floor system.
- Substrate moving after the installation. The concrete moved after the installation was complete along one of the many column lines. Nuflorz anticipates that some movement will happen on a new floor. Nuflorz filled the Joints with a semi ridged epoxy material with additives designed to move with the expansion and contraction. This is not something that a floor system can stop. Nuflorz was asked to return and review some movement in the slabs and complete repairs. Nuflorz mobilized and repaired the one and only expansion joint that moved. This was the meeting point of two separate concrete pours. The adjoining seam moved a large amount for a reason unknown to us. It was filled with a urethane filler on top of backer rod.
Outcome
Another happy customer.
Lessons Learned
Communication with the customer and end users leads to a job well done.
This case study highlights the importance of thorough communication, flooring system design, preparation, precise application, and continuous improvement in ensuring the success of Poured epoxy flooring installations in an industrial heavy use environment.
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