Undertaking an incredibly large flooring installation project that could withstand various factors beyond extremely high-traffic levels alone.
Iveco, regarded by the industry as one of the global leaders of high-quality road transport vehicles, has worked closely with Flowcrete South Africa to ensure that its new Pretoria production facility has a flooring system that matches the meticulous standards of its products.
The industrial vehicles manufacturer is in its final stages of constructing a new Rosslyn-based factory, which will be used to build larger trucks in its range. The company and its main contractor, Edilcon Construction, embarked on a rigorous specification process to determine the best flooring solutions for this new facility – which at 55 000m² is one of the largest flooring projects currently being undertaken in South Africa.
Flowcrete’s applicators, SpecFloors, began the installation process in November 2013 with completion scheduled for August 2014.
Prior to applying the finish, Flowcrete had to assess the damage that a fire at the site had caused. Since the underlying concrete slabs had been damaged by the fire, they had to be removed and the area had to be re-screeded. Conrep SF65 was applied within the cavities that had been left after the removal of sliding doors and support beams that had also been compromised by the fire.
Several systems were chosen to provide an effective floor for each area of the vast industrial complex. The solvent-free and chemical-resistant epoxy resin coating Flowcoat SF41 was applied within the main production areas of the facility and on the walkways. Resin systems like this are ideal for creating seamless, easy-to-clean surfaces that allow for an efficient workplace and, thanks to the durability of Flowcoat SF41, Iveco could be rest assured that its unblemished surface wouldn’t deteriorate when faced with the inevitable demands that manufacturing 20-ton trucks entails.
Flowcoat SF41 offers industrial facilities the opportunity to make the site safer and easier to work in due to its adjustable anti-slip profile. This product was also used for the site’s demarcation lines, as Iveco required a highly durable system that was thicker than the standard solution.
For several areas of the facility, where the floor required additional properties, Iveco specified the Flowcrete system, Flowfresh. The laboratory and paint mixing rooms installed Flowfresh HF ESD across the floors, and Flowfresh WR ESD was used as coving and applied around the drains.
Flowfresh has been specifically designed to facilitate the highest levels of hygiene by incorporating an antimicrobial additive throughout the material that inhibits the growth of up to 99,9% of bacteria on the floor’s surface.
These particular Flowfresh systems also have electrostatic dissipative properties to avoid static charge build-up in the floor, damaging the laboratory’s sensitive electrical equipment or becoming a dangerous ignition source in the paint rooms.
The facility’s aesthetics was a key factor of Iveco’s design. A range of colours was applied to mark out the different areas and it was important that the floors maintained a crisp, clear colour so that the interior would present a smart and high-end appearance despite the intense manufacturing activities. The colours used on the floor also had to match the manufacturer’s international standard, so to accommodate this, Flowcrete developed and manufactured the systems to specific RAL colours.
This project posed several complex tasks for Flowcrete South Africa, as not only did it involve exceptionally large quantities of flooring material, but it also meant creating bespoke colours and providing an optimised floor finish that met every aspect of Iveco’s high standards.