40m² PU Screed Bakery Flooring in St Austell, Cornwall
Shier Coatings completed the repair and refurbishment of approximately 40m² of flooring within a busy commercial bakery in St Austell, Cornwall.
The project involved breaking out extensive areas of blown concrete, rebuilding the damaged substrate with epoxy DPM mortar, priming and fully blinding the complete floor with coarse aggregate, and installing a red polyurethane screed at a nominal thickness of 6mm.
The Problem
The original plan was to mechanically grind and fine-fill the existing concrete floor before installing the new flooring system.
However, once work began across the floor, it became clear that a substantial amount of the concrete had blown and was no longer structurally sound.
Fine filling would not have corrected this underlying problem. Installing a new resin floor over failed concrete could have caused the system to crack or debond as the damaged substrate continued to deteriorate.
The blown concrete therefore had to be broken out and properly rebuilt before the new polyurethane screed could be installed.
What We Did
The complete flooring process consisted of:
1. Mechanically grinding the existing concrete floor
2. Identifying and breaking out blown concrete
3. Cleaning and preparing the resulting potholes and cavities
4. Rebuilding the damaged areas using epoxy DPM repair mortar
5. Allowing the repairs to cure fully
6. Priming the complete 40m² floor
7. Fully blinding the wet primer with coarse aggregate
8. Removing loose aggregate once the primer had cured
9. Installing red polyurethane screed across the entire floor
10. Applying the PU screed at a nominal thickness of 6mm
Breaking Out the Blown Concrete
The failed concrete was broken out and removed until a solid and stable substrate was reached.
This created several deeper potholes and cavities that required structural repair before the new flooring system could be installed.
Rather than attempting to cover the damaged areas with fine filler, the substrate was properly opened, cleaned and prepared.
Epoxy DPM Mortar Repairs
The potholes and cavities were rebuilt using epoxy DPM repair mortar.
This restored the damaged sections, brought the floor back to the required level and created a strong base for the new flooring system.
The repairs were allowed to cure fully before the next stage commenced.
Full Primer and Coarse-Aggregate Blind
After the epoxy DPM mortar repairs had cured, the entire 40m² floor was primed.
While the primer remained wet, the complete surface was fully blinded with coarse aggregate. Once the primer had cured, all loose and excess aggregate was removed.
The coarse aggregate created a heavily textured mechanical key between the repaired concrete substrate and the polyurethane screed installed on top.
The system build-up was:
- Mechanically prepared concrete
- Epoxy DPM mortar repairs
- Primer applied across the complete floor
- Full coarse-aggregate broadcast
- Red 6mm polyurethane screed
Red 6mm Polyurethane Screed
Following the priming and aggregate-blinding process, approximately 40m² of red polyurethane screed was installed across the entire bakery floor at a nominal thickness of 6mm.
PU screed was selected to provide a durable surface capable of handling:
- Heavy daily foot and operational traffic
- Regular cleaning and washdown
- Moisture and spillages
- Food-production contaminants
- Busy working and loading areas
- Continuous commercial use
The completed system created a seamless surface without the damaged areas, potholes and weak sections found in the original concrete.
The Finished Result
The completed flooring system transformed the damaged concrete into a strong, hygienic and practical bakery floor.
The finished system provides:
- Approximately 40m² of seamless PU screed
- A nominal system thickness of 6mm
- A full coarse-aggregate mechanical key
- Resistance to heavy daily traffic
- Suitability for regular washdown
- Easier cleaning and maintenance
- Protection for the repaired concrete
- A clean and professional red finish
- Long-term performance in a demanding bakery environment
By breaking out the blown concrete, completing epoxy DPM mortar repairs, priming and fully blinding the complete floor before installing the PU screed, Shier Coatings provided a properly prepared flooring system built for demanding commercial use.
PU Screed Flooring for Food-Production Facilities
Shier Coatings installs hygienic polyurethane screed flooring for bakeries, commercial kitchens and food-production facilities throughout Cornwall, South Wales and across the UK.
Our services include:
- Polyurethane screed flooring
- Food-production flooring
- Mechanical diamond grinding
- Removal of blown concrete
- Epoxy DPM mortar repairs
- Aggregate-blinded primers
- Hygienic resin flooring
- Heavy-duty floor refurbishment
Contact Shier Coatings to arrange a site assessment or discuss an upcoming bakery, commercial kitchen or food-production flooring project.
