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CASE STUDIES
Click on a bullet point header below to go to examples of some
typical problems resolved by D & R Maintenance Solutions Ltd.
RENOVATION & PROTECTION OF ROOFS
SLIP RESISTANT SYSTEMS
FLOOR COATINGS & SCREEDS
WALKWAYS & STAIRS
CONCRETE & STONE REPAIRS
REPAIR & COATING OF TANKS
RENOVATION & PROTECTION OF BUNDS
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MINERAL FELT REFURBISHMENT
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Mineral felt refurbishment
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Years of atmospheric attack and pollution had caused the felt
roof of an NHS Trust building to deteriorate badly and leak
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The cost of replacement was prohibitive and the client was
looking for a long term cost effective system to renovate the total
roof.
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A liquid applied fully reinforced overlay was installed. This
provided a seamless fully bonded overcoating to the lead.
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• No disruption during installation
• Long term waterproofing solution
• Extended life expectancy
• Outstanding environmental protection
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LEAD ROOF REFURBISHMENT
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Lead roof refurbishment
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Years of atmospheric attack and pollution had caused the lead
roof of a prestigious school building to deteriorate badly and
leak.
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The cost of replacement was prohibitive and the client was
looking for a long term cost effective system to renovate the total
roof.
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A liquid applied fully reinforced overlay was installed. This
provided a seamless fully bonded overcoating to the lead.
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• No disruption during installation
• Long term waterproofing solution
• Extended life expectancy
• Outstanding environmental protection
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ASBESTOS CEMENT ROOF REFURBISHMENT
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Asbestos cement roof refurbishment
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A local council needed to extend the life of one of its depots
and the roof was causing serious issues with continual leaks. The
cost to replace the roof was prohibitive and a more cost effective
solution was required.
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An overlay refurbishment system with a minimum life expectance
of 5 years with a manufacturer’s backed warranty. Also, the
depot had to remain in operation at all times and therefore removal
of the roof was not an option.
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A liquid applied locally reinforced overlay was applied. This
provided a seamless fully bonded over-coating to the asbestos
cement sheeting. During the application, it was decided to also
recondition the parapet walls, lead work and glazed roof lights.
This was done with no additional disruption.
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• Cost effective non intrusive application
• Fully warranted for 5 years with a life expectancy of well
in excess of this
• No disruption during installation
• Improved aesthetics
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LEAD GUTTER LINING AND PROTECTION
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Lead roof refurbishment
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Years of atmospheric attack and pollution had caused the lead
roof of a prestigious school building to deteriorate badly and
leak.
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The cost of replacement was prohibitive and the client was looking for a long term cost effective system to renovate the total guttering system.
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A liquid applied fully reinforced lining was installed. This provided a seamless fully bonded overcoating to the lead.
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• No disruption during installation
• Long term waterproofing solution
• Extended life expectancy
• Outstanding environmental protection
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GLAZING BAR REFURBISHMENT
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Metal (zinc) glazing bar refurbishment
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Years of atmospheric attack, pollution and thermal movement had caused the seals of the glazing bars within the roof lights to deteriorate badly and they had been leaking for some while.
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The cost of replacement was prohibitive and the client was looking for a long term cost effective system to renovate the roof light area. It was also important for the repairs to be aesthetically pleasing and in keeping with the surrounding structure
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A liquid applied fully reinforced overlay was carefully applied. This provided a seamless fully bonded coating over the glazing bars, bonding directly to the glass.
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• No disruption during installation
• Long term waterproofing solution
• Long warranted life expectancy
• Virtually indistinguishable from the original finish
• A long standing problem solved
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BUNDED FLOOR TO WALLS
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Construction of bunded floor to walls in a 4th floor plant room
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A previously applied Bitumous coating had failed and created an issue with adhesion of a replacement coating. In the event of a tank or boiler leak the floors below would be liable to flooding.
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To provide a lining that would over come the bond issue to the Bitumous coating and provide a bunded area within the plant room.
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By the creation of a laminated/anchored flooring system which bonded to the concrete slab via a steel mesh.
This provided a seamless lining of the floor to walls and thereby a fully waterproof bunding sytem was created.
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• No disruption to operation of the building
• Solution to a previously insoluble issue
• Elimination of flooding risk from plant room
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TANK FARM, INCLUDING BUNDS
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Refurbishment of Tank Farm, including Bunds
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Bund walls were leaking and therefore the bunds were below the current required PPG standard.
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To apply linings to bunds, tanks and walkways to upgrade the facility and comply with current legislation.
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By constructing reinforced wall-to-base joints and coating of the bund interiors, a seamless lining was created. All metalwork was also coated and the long term integrity of the whole installation assured.
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• Very little disruption to operation of the site
• Compliance with current legislation
• Compliance with health and safety requirements
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CONCRETE ACCESS RAMP
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Refurbishment of concrete access ramp
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Heavy degradation of the concrete surface of the ramp caused a serious slip and trip hazard, especially during winter-time.
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The reinstate a safe walkway and upgrade to meet the current DDA requirements.
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To re-screed the entire surface area with a hard wearing surfacing screed and apply a DDA compliant grip system.
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• A fully DDA compliant access ramp
• Short project duration with minimal disruption to access
• The finish of refurbishment blended well with surroundings
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MACHINE SHOP FLOOR
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Slip Resistant System on oily machine shop floor
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Due to unavoidable process oil contaminating the floor a slip hazard was apparent.
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To produce an effective slip resistant floor coating, which was also aesthetically pleasing , easy to clean and would enable demarcation areas to be created.
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By applying a fast curing polymeric system incorporating a very hardwearing aluminium oxide aggregate in stripe pattern and alternate colours, a long life operative-friendly environment was created.
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• Build-in demarcation
• Minimal disruption to operation
• Cost effective long term solution
• Safe working environment
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SLIP RESISTANT SYSTEM ON LOADING BAY
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Slip Resistant System on Loading Bay
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On a wet concrete loading bay, a major slip hazard existed and the client was very concerned that a forklift truck would be involved in an accident.
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The disruption to the operation by carrying out the refurbishment needed to be kept to minimum.
Also the system had to be both hard wearing and very effective when wet.
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By applying a fast curing polymeric system incorporating a very hardwearing aluminium oxide aggregate in chevron pattern a long life high traction surface was created.
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• Minimal disruption to operation
• Cost effective long term solution
• Safe working environment
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METAL MAN HOLE COVERS
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Slip Resistant System on metal man hole covers
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When wet, particularly during the winter period when ice became an additional hazard the metal surfaces of the manhole covers became a major slip hazard.
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To produce an effective slip resistant coating system in an outside environment, which was also aesthetically pleasing, within a very restricted budget.
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By applying a fast curing polymeric system incorporating a very hardwearing aluminium oxide aggregate in diagonal stripe pattern was applied, providing a very economic durable grip system.
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• Low cost per cover
• Minimal disruption to operation
• Hard wearing long life solution
• Safe working environment
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FACTORY WALKWAY
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Installation of demarcation of factory shop floor.
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Due to H&S requirements, pedestrian walkways and line marking were required.
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To create designated pedestrian walkways, in line with corporate colour schemes. These should be slip resistant, easy to maintain and able to withstand traffic from forklift trucks.
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By applying a rapid curing (MMA based) system which was colour matched to suit the requirements, very fast "Back-To-Service" times were achieved.
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• Minimal disruption during installation
• Cost effective long term solution
• Safe environment
• Colour coordinated to corporate identity
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QUARRY TILED KITCHEN FLOOR
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Repairs to Quarry Tiled kitchen floor
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Localised damage, cracking, debonding of Quarry tiles within the kitchen were causing both a trip hazard and cleanliness issues.
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To repair only degraded areas with no damage to surrounding area and minimal disruption to the operation of the kitchen.
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Removal of all loose/damaged tiles and re-screeding with a colour matched non-porous polymer screed. This created not only a durable, easy-to-clean replacement but also the appearance of the repair was in keeping with the original flooring.
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• Very little disruption to operation of the kitchen
• Only damaged areas treated, thus providing a very cost effective sloution
• Compliance with health and safety requirements
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GARAGE FLOOR
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Installation of demarcation of garage floor and pit.
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Many years of heavy use with the associated contamination caused by vehicle maintenance had created a dangerous working environment which was also extremely dirty and slip hazardous.
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To create designated working area, which would be easy to maintain and create a safe, user friendly environment. The system had to possess slip resistant characteristics.
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By applying a polymeric resin based coating system incorporating a grip aggregate in contrasting colour scheme, all the customer requirements were met.
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• Easy to clean and maintain.
• Cost effective long term solution
• Safe environment
• Colour coordinated to corporate identity
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WAREHOUSE FLOOR REFURBISHMENT
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Refurbishment warehouse floor
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The use of a very large warehouse had changed and it is now used for the storage and distribution of high value truck parts. Three issues then became apparent. Firstly the floor, particularly around the expansion joints, had deteriorated and the “picking trucks” were becoming dangerous to operate. Secondly, the floor was “dusting”, creating cleanliness issues. Finally, forklifts entering the building with wet tyres were regularly skidding.
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To repair the damaged concrete, creating a smooth and level surface, especially around the expansion joints. Then to apply a hard wearing, skid-resistant floor coating which would be colour coded to identify gangways and storage areas.
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The application of a polymer concrete repair system, highly flexible and durable expansion joint filling and durable coating, incorporating a grip system. Not only was a very attractive finish achieved but also a safe, durable surface was created.
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• Removal of skid risk
• Creation of a smooth, level area for safe truck operation
• Removal of "dusting" issue
• Long term repair of expansion joints
• Identification of walkways
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REFURBISMENT STEPS & WALKWAYS
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Refurbishment of steps and walkways.
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Due to deterioration over several years the walkways and access stairways around the facility were causing a slip and trip hazard.
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To repair localised damage to the base concrete and apply an aesthetically pleasing surface which would give long term durability and possess slip resistant characteristics.
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By applying a resin bonded aggregate system to both walkways and steps, not only was a very attractive effect achieved but also safe walking surface was created.
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• Minimal disruption during installation
• Cost effective long term solution
• Safe environment
• Aesthetically pleasing
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REFURBISMENT RAMP & WALKWAY
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Refurbisment ramp & walkway.
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Over several years general wear and tear combined with weather the walkway and ramp had become not only unsightly but also potentially dangerous, especially during the winter period. The gradient of the ramp exacerbated the issue.
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To repair localised damage to the concrete and apply an aesthetically pleasing surface which would give long term durability and possess slip resistant characteristics.
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By applying a resin bonded aggregate system to both walkways and steps, not only was a very attractive effect achieved but also safe walking surface was created.
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• Minimal disruption during installation
• Cost effective long term solution
• Safe environment
• Aesthetically pleasing
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RAMP & STEPS REFURBISHMENT
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Refurbishment of ramp and steps
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Over several years general wear and tear combined with atmospheric attack, the steps and ramps had become not only unsightly but also potentially dangerous, especially during the winter period. As this is a very popular tourist area, aesthetics are very important and the use of conventional systems was making this very difficult.
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To apply a new wear resistant surface to the steps and ramps, incorporating a grip system. The surface needed to be aesthetically pleasing and provide long term durability and possess slip resistant characteristics.
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The application of a polymer screeding system and grip coating to both ramps and steps, not only was a very attractive finish achieved but also a safe, durable surface was created.
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• Minimal disruption during installation
• Cost effective long term solution
• Durable and safe
• Aesthetically pleasing
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BRAITHWAITE POTABLE WATER TANK
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Refurbishment of "Braithwaite" Potable Water Storage Tank
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Due to the age of the storage tank, internal corrosion was such that the integrity of the tank structure was in question.
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To provide a lining that would both protect against future corrosion and comply with WRAS approvals for potable water storage.
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By grit blasting, localised repairs by “cold bonding” of plates and coating of the interior of the tank, the life of the tank is now extended for a minimum 10 years. A warranty was issued to cover both coating system and workmanship .
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• No disruption to operation of the hospital
• Significantly reduced cost versus replacement unit
• Compliance with health and safety requirements
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POTABLE WATER STORAGE TANK
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Refurbishment of Potable Water Storage Tank
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Due to the age of the storage tank, internal corrosion was such that the integrity of the tank had to be refurbished.
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To provide a lining that would both protect against future corrosion and comply with health and safety requirements within the food industry.
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By grit blasting, localised repairs by "cold bonding" of plates and coating of the interior of the tank, it was possible to provide a long term life extension.
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• Minimal disruption to production programme
• Significantly reduced cost versus replacement unit
• Compliance with health and safety requirements
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FIRE WATER STORAGE TANK
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Refurbishment of Fire Water Storage Tank
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Due to the age of the storage tank, corrosion (both internal and external) had led to leaks and health and safety concerns.
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To provide a cost effective long term alternative to the prohibitively expensive replacement of the existing tank.
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By grit blasting, localised repairs by "cold bonding" of plates and coating of both the exterior and interior of the tank, it was possible to provide a long term life extension to the unit at a fraction of the cost of replacement.
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• Minimal disruption to fire sprinkler system
• Significantly reduced cost versus replacement unit
• Compliance with insurance requirements
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FUEL OIL STORAGE TANKS
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Refurbishment of Fuel Oil storage tanks (steel with insulation cladding)
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Due to the age of the storage tanks, corrosion (both on the vertical surfaces and the top) had led to leaks in the outer cladding. The client was concerned that if left unchecked, this could lead to leaks from the tank itself with the resultant health and safety concerns.
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To provide a cost effective long term alternative to the prohibitively expensive replacement of the existing tanks. Also top provide an aesthetically pleasing appearance.
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By careful, localised abrasion and preparation, repairs by “cold bonding” of plates and coating of the vertical surface were completed. A liquid applied roof repair system was applied to the top of the tank. It was possible to provide a long term life extension to the units at a fraction of the cost of replacement.
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• No intrusive works required
• Significantly reduced cost versus replacement unit
• Much improved appearance of the tanks
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CONCRETE BALCONIES
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Refurbishment of concrete on balconies.
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The balcony structures had suffered damage from water ingress, resulting in corroded reinforcing bars and spalled concrete. The appearance was also an issue.
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To repair and protect against future attack. Also to recreate a secure base for the balcony railings. To improve the aesthetics by applying a long-life decorative coating.
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The repairs were carried out using a lightweight polymer-modified cementicious rebuilding system. The vertical elevations were then coated with a flexible, micro-porous system, for an attractive finish combined with protection against future water attack and damage.
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A very cost effective repair to seriously degraded concrete.
An attractive long lasting decorative finish.
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CONCRETE STEPS & LANDINGS
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Refurbishment of concrete on steps and landings.
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The concrete structure had suffered damage from the surface preparation system used to remove the decorative coating system. The resultant surface had to be smooth before the new coating could be applied.
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To apply a “skim-coating” to stair treads, risers and landings to provide a perfectly smooth hard-wearing base for the paint system.
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The surfacing works were carried out using a high bond-strength polymer-screeding rebuilding system. This was capable of being applied from 0.25mm up to 6mm in one coat.
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A fast cost effective repair to seriously degraded concrete which otherwise would have to be replaced at substantial cost.
Minimum time required between repairs being completed and paint system applied.
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RENOVATION OF STONE DETAILS
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Renovation of stone details - Registry Office
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The Registry Office is located in a former church and the sandstone widow detailing had suffered badly over the centuries from attack by the wind and rain.
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To repair in a sensitive manner, blending with the surrounding weathered but sound areas. Also to protect from future attack.
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The repairs were carried out using a colour-matched polymer rebuilding compound. The whole area was then treated with a micro-porous (breathable) system, to prevent future water damage and attack.
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Minimal disruption to the busy schedule of the Registry Office
The repairs are very much in keeping with the rest of the building fabric and are virtually invisible
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CONCRETE COLUMNS & LINTELS
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Refurbishment of concrete on lintels and columns.
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The preformed concrete structures had suffered damage from water ingress, resulting in corroded reinforcing bars and spelled concrete. The integral gutters had failed in several areas and were totally ineffective. The appearance of the whole facade was also an issue.
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To repair back to original detail and to protect against future attack. Also to recreate the drainage gutters. To improve the aesthetics by applying a long-life decorative coating.
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The repairs were carried out using a lightweight polymer-based rebuilding system. The front and sidel elevations were then coated with a flexible, micro-porous system, for an attractive finish combined with protection against future water attack and damage.
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• A very cost effective repair to seriously degraded
concrete.
• Drainage gutters recreated as part of repair
• An attractive long lasting decorative finish
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