TPS360 has provided a total project solution, including a class-leading resin floor, for a redeveloped recycling and waste management facility near Cardiff.
Operated by Viridor, Cardiff Energy Recovery Facility (ERF) is the largest of its kind in Wales and treats waste from the local authority and local business contracts. The facility, which has been operational since 2014, handles around 350,000 tonnes of residual, non-recyclable waste each year.
The challenge on this particular project was to provide a hard-wearing finish for a demanding and potentially hazardous, live environment where 50 tonne front loaders and other heavy plant equipment are operated. The work also had to be scheduled in such a way that the facility could maintain 24-hour operation without any downtime.
It was once again TPS360’s experience and excellent project portfolio which opened the door for them on this project. The company worked closely with the client from an early stage, installing test samples and carrying out trials to ensure the best resin specification. As Principal Contractor, TPS360 was responsible for engaging with other live trades on site, including scaffolders, site production operatives, ground workers and cleaning contractors, as well as managing Health & Safety on site.
The total size of the resin area was 1,000m² and the project took three months. The products used were:
- For the screed – Master Builders MasterEmaco – a fluid fast-setting traffic repair mortar;
- For the primer – Master Builders Ucrete Primer FS – a heavy duty polyurethane fast slurry primer for Ucrete flooring systems;
- For the finish – Master Builders Ucrete IF.
The detail of the work included thorough cleaning prior to commencement, breaking out of defective concrete and rebar, returning the concrete to its original levels using MasterEmaco, preparing the newly installed substrate using HTC planetary grinders, applying a hard wearing screed topping as a primer (Ucrete Primer FS), the installation of Ucrete IF as the tough upper resin coating, and finally sealing all joints.
Ucrete IF is a unique HD polyurethane resin floor which provides an extremely tough surface for environments subject to extreme impact and abrasion. It features a dense and impervious iron-armoured surface, which provides protection against severe abrasion, making it the ideal floor finish for applications in the waste management, heavy engineering and manufacturing industries and wherever a robust long lived floor is required.
Gavin Ashcroft, Sales Director (South Wales & West) says,
“On the Viridor Recycling & Waste Management Plant we were able to demonstrate firstly how we can provide a total project management solution on a site such as this, liaising with the client and managing all other trades on-site, ensuring that the facility could remain fully operational during the works.”
“Secondly it is a showcase for the most heavy duty resin flooring systems, demonstrating how an iron-armoured polyurethane resin system can provide a good solution in the most demanding and aggressive of environments.”