Newcastle Food Factory

Description

This project involved addressing floor level discrepancies between an existing building and a new extension within a food factory in Newcastle. The goal was to create a seamless, durable, and hygienic flooring system suitable for food production environments.

Project Scope

• Performed perimeter saw cuts and applied approximately 40mm of Resdev Pumabulk to bridge the height difference between the two structures.
• Mechanically ground the entire floor area using a three-phase diamond grinding machine equipped with a vacuum attachment to minimize dust.
• Applied Resdev Pumaprime DPM with a scatter of Resdev Pumagrip aggregate to establish a damp-proof membrane and enhance adhesion for subsequent layers.
• Hand-laid a 6mm polyurethane screed using steel float trowels, providing chemical, impact, and slip resistance ideal for food processing areas.
• Installed 100mm resin coving finished with stainless steel trim and applied flexible resin jointing compound around drains to ensure a seamless, hygienic, and crack-resistant finish.​

Project Overview

The project commenced with resolving the floor level disparity between the existing facility and the new extension by executing precise saw cuts around the perimeter and applying Resdev Pumabulk to achieve a uniform surface. Following the curing of the leveling compound, the team mechanically prepared the entire floor area to remove contaminants and create an optimal substrate for coating adhesion. A damp-proof membrane was applied to mitigate moisture issues, followed by the application of a 6mm polyurethane screed, known for its durability and suitability in food production settings. To complete the system, 100mm resin coving was installed to create seamless transitions between floors and walls, reducing bacterial harborage points, and flexible jointing compounds were applied around drainage areas to accommodate movement and prevent cracking. The project was completed efficiently, resulting in a robust and hygienic flooring solution that met the client’s operational requirements.