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UltraFloor gets into shape at David Lloyd

SEVERAL materials across Instarmac’s product ranges have been used to repair a concrete floor at health, sport, and leisure group, David Lloyd.

With 126 clubs and more than 600,000 members, David Lloyd is the perfect destination to stay fit and healthy. In February 2022, the mezzanine floor at its Manchester site had become damaged and needed to be repaired.

The challenge
This was a particularly challenging installation as the repair took place on a mezzanine floor above the swimming pool. The vibrations caused by weights dropping on the floor had resulted in the concrete underneath the gym tiles to break up causing irreparable damage.

What’s more, this area of the building is naturally very hot and humid and therefore the drying times of products are often affected.

The solution
To begin the repair, flooring contractor HB Flooring removed the broken concrete from beneath the existing gym floor to expose the steel subfloor. To prevent future damage, and to ensure the new concrete keyed to the subfloor, HB Flooring applied UltraScape resi-bed – a resinous mortar than can reportedly withstand vibration.

Says UltraFloor: ‘To build up the subfloor, UltraCrete QC10 F, rapid set flowable concrete was then applied at an 85mm depth. UltraCrete has a long history of manufacturing tried, trusted, and tested high specification concretes. With that in mind, it was unsurprising HB Flooring chose to use QC10 F – a concrete that has been proven strong enough to withstand gym weights being dropped on it, without breaking up.

‘To prepare the area for tiling, Level IT Top was then applied to the 70sqm area. Level IT Top is a polymer rich, high strength, single part, cementitious smoothing underlayment which incorporates recycled raw materials. Formulated for exceptional abrasion resistance, Level IT Top has been designed for use a finished wear surface in both industrial and commercial applications.

‘What’s more, Level IT Top has a working time of between 30-40 minutes, can receive foot traffic after 2-3 hours and forklift traffic after 36 hours – perfect for projects with a quick turnaround such as this one. To complete the installation, HB Flooring fitted Idass specialist gym tiles, as per the David Lloyd specification.’

The project was completed in one week in February 2022. ‘Owing to HB Flooring’s expertise and Instarmac materials, David Lloyd members are once again able to enjoy the gym’s world-class facilities.’
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