Kawneer UK Ltd

A refurbishment project was carried out within an existing industrial facility to accommodate the installation of a new precision racking and moveable storage system. The programme was time‑critical and required extensive concrete sawing to allow precision steel rails to be installed within the existing concrete floor. These rails demanded extremely accurate control of finished floor levels and tolerances.

Following installation of the rails, adjacent cut‑out areas were repaired using a rapid‑setting repair concrete. The existing floor surface was then thoroughly cleaned to remove residual coatings and sealers before being mechanically prepared by scabbling to provide a sound, textured substrate suitable for bonding.

The prepared substrate was pre-treated with a primer designed to regulate porosity, enhance adhesion and reduce the risk of pinholing within the levelling layer. This ensured a consistent surface condition across both repaired and original concrete areas prior to application of the levelling system.

A pump-applied, rapid-hardening industrial floor screed was installed in sectioned bays to precisely match the finished height of the installed rails. The system was selected for its self-smoothing characteristics, high strength performance and suitability for use where downtime must be minimised. The screed provided a durable, abrasion-resistant surface capable of accommodating normal industrial traffic without the need for an additional floor finish.

The installation supported a fast return to service, with foot traffic possible within 2–4 hours and progressive loading thereafter. The completed floor achieved a high-quality, level finish meeting the stringent tolerances required for precision storage and manufacturing operations, allowing the facility to be brought back into production within a short timeframe.