Flowstone Industrial Flooring Ltd was commissioned to carry out specialized flooring works for a hand sanitiser manufacturing facility located in County Durham. The primary objective of the project was to create chemical-resistant bunds around the tanks used for producing hand sanitiser. This case study highlights the importance of bunds in safeguarding the environment and provides insights into the specific solutions implemented by Flowstone to meet the client’s requirements.
Understanding Chemical Bunds:
A chemical bund is a structure designed to protect against environmental hazards such as oil spills and chemical leaks. Its purpose is to prevent contamination of land, water sources, and air quality in surrounding areas. Particularly for facilities located near populated regions, bunds are crucial in ensuring the safety of nearby communities and minimizing their exposure to potentially harmful substances.
Refurbishing the Chemical Resistant Bund:
The existing bund area required refurbishment, necessitating the expertise of Flowstone’s specialist epoxy resin contractors. The primary objective was to provide a resilient coating capable of withstanding various chemicals, including alcohol, ethanol, and isopropanol, in the event of spillage or leaks.
Specifying a resilient epoxy resin coating
The works area covered a total flooring area of 2,400m², which was executed in phases throughout the project. Phase 1 encompassed approximately 1,000m², including 250m of joints.
Flowstone specified Virtus Resins Strongcoat, an exceptionally durable two-part epoxy resin with a smooth gloss finish, for the project. The specification was determined by an experienced member of Flowstone’s in-house technical team. The first part of the epoxy resin involved the on-site mixing of resin, hardener, and additive to create the final chemical-resistant coating. The second part entailed the application of the product using medium pile resin rollers to achieve an aesthetically attractive finish while ensuring the coating’s durability.
Advantages of Virtus Resins Strongcoat:
Virtus Resins Strongcoat offers several advantages over other products available in the market. It is rustproof, weatherproof, and resistant to pitting, ensuring that it remains even, and smooth, and prevents corrosion even when exposed to various environmental conditions. Furthermore, Strongcoat provides excellent chemical resistance, including resistance to alcohol, which was a critical requirement for this project. To meet the client’s preferences, the final finish was customized in RAL 5024 (Pastel Blue) colour.
Preparing the Chemical Bund for Epoxy Resin Coating:
Before the application of the epoxy resin, the existing bund area underwent bolt repairs and general improvements. Flowstone utilised diamond grinding equipment to remove rust and debris from the existing epoxy coating, followed by a thorough cleaning with solvents. The intricate work involved diamond grinding and painting around the bund plinths and fixed machinery.
Minimising Disruption:
To ensure minimal disruption to the hand sanitiser production, some areas of the facility needed to remain operational during the flooring works. Flowstone carefully planned the project and completed the works over multiple visits, minimising the impact on manufacturing processes.