High Performance Chemical Resistant Flooring For Global Can Manufacturer

We all drink soft and alcoholic drinks out of tin cans. But do we understand the amount of work that goes into the making of these products, which are then just crushed and recycled.

Aluminium tin cans are just one of the items produced by global manufacturer Ball Packaging. The company employs over 17,500 people across the globe and has over 100 plants worldwide. They produce tin cans for some of the largest beverage brands on the market.

Rigorous cleaning requirements

The Ball Packaging site in Wakefield, West Yorkshire is the main producer of what is arguably the most famous tin can, which most of us have grown up drinking and enjoying. After the tin has been made and prior to it being filled with the beverage, it goes through a rigorous cleaning method to ensure there is no trace of bacteria left on the product.

All this cleaning and the agents used to come at a heavy cost for the flooring in the building housing the manufacturing equipment!

Chemical resistant flooring to withstand aggressive cleaning methods

Continuously looking to further improve plant and machinery processes, Ball Packaging was investing in a new, multi million-pound state of the art cleaning facility, to enhance product quality and increase capacity.

But before the new cleaning equipment arrives, there is a whole host of preparation work to be undertaken, which is when Ball Packaging contacted Britcon Construction.

Britcon is one of the UK’s most successful and progressive construction and development businesses. Established for nearly 30 years as a family business, Britcon has an exceptional pedigree with an impressive and diverse client portfolio.

A specification to match the challenge

Part of Britcon’s scope of works was to specify the right flooring system, to be installed in the area housing the new cleaning machinery. With a full awareness of the chemicals used in the cleaning processes, Britcon called in expert advice on what flooring products could withstand years of high intense cleaning agents applied at high temperatures, 24 hours a day, 7 days a week.

As an approved resin flooring contractor to Britcon, the Ultrasyntec team was invited for a formal site visit to discuss all elements of the substrate to establish which chemical resistant paint flooring systems would meet the challenges.

When Ultrasyntec had a clear understanding of what Ball Packaging and Britcon needed to achieve, the team worked closely with the technical department at their preferred suppliers to confirm the specification, along with negotiating a full warranty on all works.

Long term flooring solutions

The big issue with regard to the flooring specification was that the flooring product had to be tough enough to stand up to the rigorous demands of falling water, standing chemicals and day to day heavy traffic. Anything less could simply delaminate or even disintegrate.

The solution that was agreed upon consisted of a damp-proof membrane primer. This would protect all new concrete structures and pits. A heavy-duty 9mm thick polyurethane screed was then applied, with all upstands and pit walls rendered using a heavy-duty polyurethane wall render. All walls and upstands were then treated with a chemical-resistant coating designed to protect the render for many years to come.

Keeping the production line running

The whole operation was completed within two weeks, working around the demands of a live production facility, with the site run under CDM (Construction Design Management) regulations, making Health & Safety the number one priority.

The area was handed back to Ball Packaging on schedule to enable the installation of the cleaning equipment.

Ultrasyntec has many years of experience in inter-trade cooperation and of completing flooring projects at clients’ live production sites, which can be challenging and demands flexibility and understanding from both parties. Britcon and Ultrasyntec achieved all elements of this project to the ultimate satisfaction of the management at Ball Packaging.