Ultrasyntec Solves Complex Decking Challenge Where Other Flooring Contractors Failed

When the team at UltraSyntec was contacted by building contractors Michael Wilson & Son Ltd, it was to discuss potential solutions for a problem which had been foxing other flooring contractors for some time. Leaks from deck to deck in one of the multi-storey car parks at Media City in Salford, Manchester had created a situation which posed issues for both vehicle and pedestrian safety.

Media City is a high-profile 200-acre innovation hub which is home to large sections of the BBC including CBBC and BBC Sport, as well as housing a shopping centre and a vibrant bar and restaurant scene. Safe, quality parking spaces are a vital part of the services offered on-site.

The problems

Leaks causing accumulations of water meant that sections of the flooring were no longer slip-resistant, which was of significant concern for the car park operators. Other flooring contractors had been invited in to provide solutions, all of which had quickly failed. Michael Wilson & Son Ltd had previous experience working with UltraSyntec and asked the team to put forward a more robust, long-term solution.

Preparing the floor

The project was further complicated as UltraSyntec had to adhere to a very tight time window, with just four and a half days to complete remediation works from start to finish. The team began by preparing the existing flooring substrate using a captive shot blasting machine to provide a suitable key for fresh resin application whilst minimising dust creation.

Creating a safe, non-slip surface

Specialists at UltraSyntec had already identified KDR Resin Systems’ DeckFlex ID system as the most appropriate material of choice. Industry-leading DeckFlex ID system was purpose-developed for use on intermediate car park decks and combines flexibility with high levels of durability. This polyurethane resin system enhances slip resistance for both foot and vehicular traffic. In addition, it is resistant to typical spills found in car parks such as fuels, anti-freeze, battery acids and hydraulic fluids.

Following the preparation of the floor, all localised repairs were carried out using a flexible epoxy mastic. The DeckFlex grip coat was first laid and fully blinded using a bauxite aggregate. Once this had cured, any excess quartz remaining in the treated areas was swept up and vacuumed. The Deckflex topcoat was then squeegee and roller applied.

Following a suitable curing time for the topcoat, all necessary demarcation lines, hatchings, road markings and zebra crossings were recreated using a thermoplastic coating.

“This was a challenging project, where we were very aware we had to specify and install a long-lasting solution capable of withstanding the rigorous operating conditions,” stated Luke Sunderland for UltraSyntec. “All works were completed on time, on budget and to a great standard. Our customer was very satisfied with the end result and handover has now been completed.”

Luke Sunderland