The Bread Company – 57m²
Project Overview
A leading bread manufacturer required a complete flooring upgrade to meet strict hygiene standards, improve cleanability, and provide a long-lasting surface suitable for high foot traffic and regular wash-downs.
Project Requirements:
- Remove existing vinyl flooring and metal plate.
- Eliminate weak and loose substrate material.
- Provide a hygienic, seamless floor that is easy to clean and maintain.
- Ensure the new floor meets food production hygiene standards.
- Deliver a durable and smooth finish suitable for production area traffic.
A leading bread manufacturer required a complete flooring upgrade to meet strict hygiene standards, improve cleanability, and provide a long-lasting surface suitable for high foot traffic and regular wash-downs.
Project Requirements:
- Remove existing vinyl flooring and metal plate.
- Eliminate weak and loose substrate material.
- Provide a hygienic, seamless floor that is easy to clean and maintain.
- Ensure the new floor meets food production hygiene standards.
- Deliver a durable and smooth finish suitable for production area traffic.
Specification
A high-performance polyurethane screed system was installed using Flortex PU Screed at an average thickness of 8 mm. Surface preparation included diamond grinding and dust removal, spot repairs using Cretex DPM Mortar, priming with DPM Primer, and sand blinding to ensure adhesion and long-term performance.
Preparation
- Remove existing floor finishes including vinyl and metal plate.
- Remove all weak/loose material and debris to reveal a sound substrate.
- Diamond grind the floor with a vacuum-assisted grinder and re-vacuum to eliminate residual dust.
Repairs and Priming
- Carry out localised repairs using Cretex DPM Mortar.
- Prime the surface with DPM Primer and blind with extra coarse kiln dried sand.
Reinforcement
- Install reinforcement mesh in localised areas where additional structural support was needed.
Screed Application
- Apply Flortex PU Screed at an average of 8 mm thickness, creating a seamless, durable surface ideal for hygiene-critical environments.
A high-performance polyurethane screed system was installed using Flortex PU Screed at an average thickness of 8 mm. Surface preparation included diamond grinding and dust removal, spot repairs using Cretex DPM Mortar, priming with DPM Primer, and sand blinding to ensure adhesion and long-term performance.
Preparation
- Remove existing floor finishes including vinyl and metal plate.
- Remove all weak/loose material and debris to reveal a sound substrate.
- Diamond grind the floor with a vacuum-assisted grinder and re-vacuum to eliminate residual dust.
Repairs and Priming
- Carry out localised repairs using Cretex DPM Mortar.
- Prime the surface with DPM Primer and blind with extra coarse kiln dried sand.
Reinforcement
- Install reinforcement mesh in localised areas where additional structural support was needed.
Screed Application
- Apply Flortex PU Screed at an average of 8 mm thickness, creating a seamless, durable surface ideal for hygiene-critical environments.
Challenges
- Old Flooring Removal: The removal of vinyl and fixed metal plates required careful preparation to avoid substrate damage and ensure complete removal of all old material.
- Surface Preparation: Prior to screed application, ensuring the floor was fully free of loose materials and dust was essential for the durability and hygiene performance of the new finish.
- Maintaining Hygiene Standards: The flooring solution needed to meet strict hygiene requirements due to the food production environment, necessitating a seamless, non-porous screed.
- Old Flooring Removal: The removal of vinyl and fixed metal plates required careful preparation to avoid substrate damage and ensure complete removal of all old material.
- Surface Preparation: Prior to screed application, ensuring the floor was fully free of loose materials and dust was essential for the durability and hygiene performance of the new finish.
- Maintaining Hygiene Standards: The flooring solution needed to meet strict hygiene requirements due to the food production environment, necessitating a seamless, non-porous screed.
Outcome
The finished polyurethane screed floor now provides a seamless, hygienic surface that is easy to clean and maintain within a demanding production environment. The new floor dramatically improves on the previous finish with enhanced durability, strength and long-term performance.
Key Benefits:
- Seamless, non-porous finish ideal for food production environments.
- Dramatic improvement in cleanliness and ease of maintenance.
- Long-lasting polyurethane screed designed for heavy foot traffic.
- Eliminated contamination risk from degrading vinyl and metal plates.
The finished polyurethane screed floor now provides a seamless, hygienic surface that is easy to clean and maintain within a demanding production environment. The new floor dramatically improves on the previous finish with enhanced durability, strength and long-term performance.
Key Benefits:
- Seamless, non-porous finish ideal for food production environments.
- Dramatic improvement in cleanliness and ease of maintenance.
- Long-lasting polyurethane screed designed for heavy foot traffic.
- Eliminated contamination risk from degrading vinyl and metal plates.
Need Advice on Food Flooring Solutions?
Speak to our technical team for expert advice on food processing and manufacturing flooring solutions. Call 01234 846 780 or email uksales@polycote.com.
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