Belzona creates solution for ongoing floor issues

KHIA ID: 9505
Industry: General Industry (GIND)
Application: FPA-Floor Problem Areas (FPA)
Substrate: Concrete
Customer Location: Mansfield
Application Date: August 2024
Products: Belzona 2211 (MP Hi-Build Elastomer),Belzona 2911 (Elastomer QD Conditioner),Belzona 4111 (Magma-Quartz),Belzona 4131 (Magma-Screed),Belzona 4911 (Magma TX Conditioner),Belzona 9411 (Release Agent)
Problem: The customer was repeatedly offering repairs to the same areas, on average every 6 to 8 weeks using a low quality cementitious repair material from the local DIY supplier.
Around these areas, new racking was to be installed and the floor was uneven. Also, the unevenness of the floor was causing catastrophic problems with fork truck wheels, bearings and suspension.

Uneven floor area made good using Belzona 4111 MagmaQuartz to support main racking stanchions

Damaged area prepared and conditioned with Belzona 4911 ready to accept Belzona 4131 MagmaScreed

Damaged area fully repaired, screeded and feather edged with Belzona 4131 MagmaScreed to provide flat safe running surface for fork lift trucks and handling machinery

One of 5 expansion joints raked out, cleaned, conditioned with Belzona 2911 Conditioner and finished with Belzona 2211 Hi-Build elastomer

Application Situation
The local Sales Engineer took time out to support and train the firm's own staff, so that they could continue to purchase materials and effect repairs in an ongoing manner.
The staff took advantage of 6 hours full training in understanding the Instructions for Use, Preparation of concrete and expansion joints, mixing, applying and finishing a total of 5 different Belzona products
Application Method
All areas were inspected to ensure all loose and friable materials were removed and the areas vacuumed
Expansion joint: 20mm backer rod was placed into the joint at a depth half that of the width and Belzona 2911 conditioner was applied and allow to become touch dry.
Whilst that was drying, the concrete areas were conditioned with Belzona 4911 TX Conditioner and Belzona 9411 release agent was applied to a wooden former for the Belzona 4111 pad for the racking.
The Belzona 4111 was mixed as per the IFU using a Daines Mixer and applied to the target area, compressing and smoothing it over with a finishing trowel. The same was done (without former) to the larger damaged area, this time using Belzona 4131.
The Expansion joint was then finished using Belzona 2211 to a masked area using applicators to create a smooth finish and removing the masking tape immediately
Belzona Facts
The constant repeated repairs were becoming a cost worry due to constant materials costs and staff costs for the time taken to offer repair time and time again. The Engineer in charge of facilities needed a more permanent and durable solution and engaged the services of the local sales engineer to offer the correct solution for a more cost effective and less labour intensive way of addressing the issues.
The engineer was so impressed that he has now instructed 4 of his workforce to attend a Buildings and structures awareness day for training
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