At Abacus Flooring Solutions, we recently completed a challenging flooring refurbishment project at AESEAL.
The original specification was to remove the existing rubber tiles to expose the floor beneath, remove the existing 3mm latex screed, and replace the tiles with a new flooring finish.
However, once the existing tiles were removed, the condition of the subfloor revealed a much bigger issue than first expected.
Unexpected Challenges Beneath the Surface
Beneath the existing floor covering, we uncovered a failed screed layer with areas reaching approximately 20mm in thickness.
This meant the floor was no longer suitable for a direct replacement installation and additional remedial works would be required before the new flooring system could be installed.
As with many refurbishment projects, the true condition of the substrate only becomes apparent once the existing materials have been removed.
Our Solution
Our team quickly adapted the project plan and carried out a full preparation process to ensure a successful outcome.
The failed screed was broken out and removed, allowing us to create a stable foundation for the new flooring system.
Careful preparation and attention to detail were essential throughout the process to ensure the finished floor would meet the durability and performance standards required for the site.
A Sustainable Approach
To replace the failed screed and prepare the surface for the client’s chosen floor finish, we used our patented recycled plastic filler, Abaplas.
Abaplas is a 100% recycled plastic filler manufactured from waste materials including conduit pipes, football stadium seating and even toilet seats.
The recycled plastic filler is mixed with epoxy resin and applied by trowel to achieve the required floor level and create a durable foundation for the new flooring system.
As a King’s Award-winning product, Abaplas helps divert plastic waste from landfill while eliminating the need for hazardous silica sand.
This sustainable solution not only restores the floor but also reduces environmental impact and improves health and safety by removing exposure to respirable crystalline silica (RCS).
Delivering a Long-Term Flooring Solution
By addressing the underlying issues rather than simply covering them up, we were able to provide AESEAL with a flooring solution built on a sound and reliable foundation.
Projects like this highlight the importance of working with experienced flooring contractors who can respond to unexpected site conditions while keeping projects moving safely and efficiently.
The completed refurbishment has provided AESEAL with a stable and durable floor ready to support the operational demands of the facility for years to come.
Put Us To The Test
If your commercial or industrial flooring project requires expert preparation, refurbishment or replacement works, get in touch with Abacus Flooring Solutions today.
Our experienced team can help identify underlying flooring issues and deliver durable, sustainable solutions tailored to your site requirements.
