Medical Quality Flooring System For Orthoplastics

Based in Lancashire, Orthoplastics Ltd has an established reputation for producing the highest grade of orthopaedic UHMWPE (ultra-high molecular weight polyethylene) products on the market. The company supplies the world’s leading orthopaedic device manufacturers and is the material of choice for a wide range of orthopaedic implants and devices used in human hips, knees, shoulders, elbows, ankles and fingers.

When Orthoplastics built a new state of the art production facility in Burnley, they turned to Ultrasyntec to recommend a medical flooring solution for the main production hall, measuring some 4000m².

Zero dusting and high hygiene levels

Due to the stringent quality and cleanliness requirements in this critical manufacturing arena, Orthoplastics presented Ultrasyntec with a number of specifications. Zero dusting from the substrate was vital, alongside the ability to clean the floor using a ride-on scrubber/dryer without causing damage to the surface. In addition, the floor needed to provide excellent aesthetics to match the expectations of visitors from the medical sector and have a life expectancy of up to 10 years, given fair wear and tear.

Tight time schedules

As an added complication, the timescale for laying the floor was also an issue. The floor had to be completed within just a few days to enable the machinery installers to bring in and commission the new manufacturing equipment on time and to schedule.

The team from Ultrasyntec began by completing a captive shot blast process across the floor to provide a sufficient key for resin application. They then applied a single coat of Resdev Pumaprime SF, a low-viscosity epoxy primer with good penetration properties designed for use on concrete and polymer-modified cementitious screed.

Pumaprime SF improves the adhesion of resin floor finishes to the substrate. It also successfully seals concrete pores and reduces the potential for pin-holing in resin floor finishes, as well as improving adhesion to the substrate.

Reduced hazards

This was followed by two coats of Resdev Pumashield SF in an attractive and practical mid-grey colour. Pumashield SF is a two-component 100% solids epoxy floor coating offering excellent abrasion and chemical resistance. It is suitable for applications including warehousing, manufacturing, workshops and showrooms as well as packing and storage areas. It is non-dusting and Nonyl phenol free for reduced hazards.

Working to a tight programme, the Ultrasyntec team completed the preparation work in a single day with a further four days to complete primer and the two top coats across the entire area. The contractors were then able to move into the building on time and begin work on machinery installation.