The original polyurethane protective coating on the steel/aluminum checker plate floor at the Maidenhead-based pharmaceutical company had failed due to the spillage of flavour oils and the use of caustic soda to clean the room two to three times a day.

The company required a solution that would not only repair the damaged floor areas but also provide robust protection against future chemical attack. As access to some of the areas was restricted by pipe work and plant, the company required an application method that could be carried out easily, without the need for specialist tools or equipment. 

A two-part, corrosion resistant epoxy coating, Belzona 5811 (Immersion Grade) was applied to a trial area of 50m² for the client to determine its suitability. Due to the simple application method that involve just an every-day roller, this coating system avoids the need to install specialist equipment thus keeping the application quick and simple, and downtime to a minimum. Satisfied with the trial area, the customer proceeded with application to the entire 2000m² area.  

Simple to apply

As the existing polyurethane coating was in most part still intact and showed good adhesion to the substrate, only the areas where the floor was most exposed to the chemicals, such as drain areas and flow paths, were treated with the Belzona system. 

Firstly, all contamination and debris was cleared away. Once mixed, the first coat of Belzona 5811 was then applied in beige colour onto the prepared surface using a roller. After the first coat had been applied, the second coat was brushed onto the substrate in grey colour to create a minimum thickness of 400mm. This technique avoided the need for hot work as the system cures quickly at room temperature 20°C, reducing health and safety risks. After just five days, the substrate achieved a full mechanical cure and after one week the floor was ready to be subjected to chemical contact, saving the company valuable downtime.

Protected against chemical attack

The Belzona system successfully restored the protection on damaged areas of the floor, fortifying the substrate with excellent chemical resistance for many years to come. The cold curing properties of Belzona 5811 allowed for a rapid and safe application method with reduced health and safety risks. 

•  Belzona’s range of polymeric repair and protection solutions for floors, walls and roofs will be showcased on Stand Q1450 at the 2015 Facilities Show from the 16th to 18th June at the ExCeL Exhibition Centre in London.