Zenith Flooring was appointed to repair and refurbish the floor within an operational area at Schenk Industrial Processing.
The existing surface required a combination of localised repairs, joint replacement and mechanical preparation before a new high-build epoxy resin coating could be installed. Careful planning was also needed to maintain site access and complete the works around the client’s operating schedule.
The challenge
Years of industrial use had left the existing floor showing signs of wear, with damaged areas and deteriorated expansion joints requiring attention.
Applying a new coating over these defects would not have provided a reliable long-term result. The substrate first needed to be repaired and stabilised, with the existing joints correctly reinstated before the resin flooring system was applied.
As the work was being completed within an active industrial environment, Zenith also needed to consider:
- access for employees, equipment and site operations;
- the sequence in which different areas could be released;
- preparation, application and curing times; and
- how the works could be phased to minimise disruption.
Planning and phased access
Zenith worked with the client to establish a programme that reflected both the flooring requirements and the operational needs of the site.
The installation was divided into manageable sections, allowing access restrictions to be coordinated around the work. Each phase accounted for surface preparation, repairs, coating application and the required curing period before the area could be returned to service.
This planned approach enabled the flooring works to progress efficiently while reducing their impact on surrounding operations.
Floor repairs and preparation
The first stage involved identifying and repairing defective areas within the existing floor.
The surface was mechanically prepared to remove contamination, loose material and failing coatings. This created a clean and suitably textured mechanical key for the new epoxy system.
Localised repairs were completed where required to restore the substrate and provide a sound, consistent base for the coating.
Thorough preparation was particularly important on this project, as the performance of a high-build epoxy floor depends on the strength, cleanliness and condition of the surface beneath it.
Expansion-joint replacement
The existing expansion joints were cut out and cleared to remove deteriorated material and create a suitable profile for replacement.
The prepared joints were then filled with an epoxy joint sealer, producing a neat and durable finish while reinstating these important details within the floor.
Treating the joints separately from the surrounding surface helped reduce the risk of existing defects affecting the appearance and integrity of the completed coating.
High-build epoxy coating
Once the repairs and joint works were complete, Zenith applied a high-build epoxy resin floor coating in mid grey.
The system created a smooth, uniform surface across the refurbished areas while improving the floor’s resistance to general industrial wear.
The mid-grey finish also helped brighten the working environment and provided a clean, professional appearance suitable for an industrial processing facility.
The completed floor
The completed installation combined essential substrate repairs with a durable high-build epoxy finish.
Damaged expansion joints were replaced and sealed, worn areas were repaired, and the existing surface was fully prepared before coating. The result is a cleaner, more consistent and easier-to-maintain floor suited to the ongoing demands of the site.
By carefully phasing the installation and coordinating access with the client, Zenith delivered the refurbishment around operational requirements while allowing completed areas to be returned to service in a controlled sequence.
