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Leeways Packaging Services Ltd – Engineering & Manufacturing Flooring

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PSC were invited by Leeways Packaging Services Ltd of Churcham in Gloucestershire to look at their new manufacturing facility floor. Leeways is a British, family owned company that offers thermoformed packaging solutions. The new 1598 square metre state of the art manufacturing facility based in Gloucestershire, was to be used thermoformed packaging and as such would need a suitable floor. 

Client Brief and Recommendation

At the site visit it was noted that the floor had extensive residues of dirt, oil and grease and failed floor paint that would need to be cleaned off before any flooring system was installed. The client was looking for a hard wearing and totally impervious that would be easy to clean and keep clean. As an experienced epoxy resin coatings contractor, PSC recommended cleaning the surface back before installing an epoxy resin priming system followed by an 8mm cementitious screed, with 3 coats of epoxy resin coating system to the entire 1598 square metre floor.

Preparation of Floor Surface

Initially the floor was given a heavy shotblast via the totally enclosed ride on shotblasting machine to remove extensive residues of dirt, oil and grease, failed floor paint, clean and prepare existing concrete floor surface. The edgework was prepared by diamond grinding with totally enclosed handheld 110v diamond grinder before the area was vacuumed clean.
The 1598 square metre area was given one coat of Resdev Pumaprime damp proof membrane priming system incorporating a heavy scatter of 0.6 to 1.2mm quartz aggregate to prevent oil ingress. Repairs were made where necessary to damaged localised concrete, holes and cracks using polyurethane mortar compound and a 76 square metre area of extensive damage, which needed a nominal 20 to 25mm DCP Cemflow base screed.

Nominal 8mm heavy duty cementitious screed system – epoxy resin coatings contractor.

To refurbish the existing concrete a nominal 8mm heavy duty DCP Cemflow topping cementitious screed was machine pump applied to the total floor area. Once dry a Resdev WD epoxy resin priming system laid before laying a further two coats of Resdev Pumatect high build, epoxy resin flooring system, in the clients chosen mid grey colour. Finally, 8mm x 10mm expansion joints were cut, knocked out and infilled with matching jointing compound to 304 linear metres.

The total work took 2 weeks and was completed on time and within budget.

“PSC Flooring did a great job with our new manufacturing facility floor. We knew that this floor would be a challenge but we couldn’t have imagined that PSC could get it looking so great.”
Lee Walding - Managing Director of Leeways Packaging Services Ltd

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