Airport Flooring Case Study: Harriman & West Airport

Customer Name: Harriman & West Airport
Customer Location: North Adams, Massachusetts
Customer Needs: A decorative floor that is able to reduce fatigue by being “soft,” with the abilities to withstand the rigors of a public airport

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With a last-minute change in trades, New England Floor & Wall was given the opportunity to install this beautiful decorative quartz floor, embedded in an elastomeric epoxy system from General Polymers. This system allows for the durability of a traditional epoxy flooring system, while still giving many of the same characteristics of flexible properties in polyurethane elastomers.

Scope of Work:

• Mobilize preparation of poured concrete
• All cracks, spalls, and deviations were repaired
• A double expansion joint was pre-packed with 100% solids epoxy mortar material
• These areas were marked for re-opening and filling after completion of the floor
• Diamond grind entire floor with an industrial floor grinder
• All edges and areas too small to be prepared with an industrial floor grinder were completed using hand grinders
• All drains and metal grate houses had to be “built” using epoxy impregnated with amorphous silica, which allows the flooring system to be flush with the final coat
• Install ships cove base around column footings to eliminate the fear of water traveling
• After determining acceptable moisture levels, NFW performed a final vacuum before installation was mobilized
• Install elastomeric epoxy floor coating
• This step had decorative quartz broadcast until the floor rejected additional quartz
• Install a 100% solids epoxy body coat
• This step had decorative quartz broadcast until the floor rejected additional quartz
• Install a 100% solids epoxy seal coat
• Install a high-performance topcoat to the entire area to seal in all quartz
• The anti-slip additive was also used in this coat to ensure optimal slip resistance

Conclusion:

Working alongside a general contractor, New England Floor & Wall was able to finish this project according to the Department of Transportations’ schedule. This beautiful public airport facility will be enjoyed for many years to come by many people in the Berkshires.

Polyurethane Flooring Hartford CT Case Study: Great American Donuts

Customer Name: Great American Donuts

Customer Location: Hartford, Connecticut

Customer Needs: A heavy-duty floor that can stand up to the rigors of Dunkin’ Donuts faced paced environment

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Working 365 days a year, the floor in the Great American Donuts desperately needed to be repaired. When New England Floor & Wall was brought in, the existing flooring had multiple areas that had started to fail, allowing for moisture to be trapped in between the substrate and the existing flooring system. NFW recommended that all of these areas be removed, as they would present themselves again if not repaired correctly.

Polyurethane Flooring Hartford CT

 

Scope of Work:

• Finish demolition of existing flooring
• All hollow spots in the existing flooring were removed to ensure bonding failures wouldn’t present themselves
• Many areas had to be removed by use of jackhammers
• Diamond grind entire floor with an industrial floor grinder
• Install patches created by epoxy mortar in all areas that had existing flooring removed
• This step was required to create the seamless industrial floor for Great American Donuts
• Make “key-way” cuts at all terminations to help lock in a flooring system
• Install various integral cove base to eliminate the fear of water traveling
• Install heavy-duty urethane slurry flooring system- this product is anti-microbial, is one of the most durable on the market, and is easy to clean and sanitize
• Install a 100% solids epoxy body coat with custom grit added to optimal ensure slip resistance
• Install a high-performance topcoat to the entire area to create a seamless look

Epoxy Flooring Alternative Hartford

 

Conclusion:

Working in phases, New England Floor & Wall was able to finish this project according to the Great American Donuts strict schedule. This manufacturing facility was remodeled to feel like it was just built!

Urethane Flooring Hartford

Industrial Epoxy Flooring Holyoke MA Case Study: Hazen Paper

Customer Name: Hazen Paper

Customer Location: Holyoke, MA

Customer Needs: A flat flooring system that will house a state-of-the-art machine

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Coming into this project, New England Floor & Wall had the task of rehabilitating an interior room of their old 19th-century mill building-turned production plant. The floor had deteriorated over time, creating areas that were dangerously thin. Certain areas were completely devoid of a subfloor, with holes looking down 30’ below into the basement. With this room going to house a state-of-the-art machine weighing in many tons, there became a need for a floor that was ‘flat,’ with deviations no larger than 1” per 12’ according to the specifications of this machine, as well as a floor that was sturdy enough to withstand the weight and vibration the machine would produce.

 

Scope of Work:

• All areas were prepared using an industrial floor grinder
• All loose/failing substrate was removed using chipping hammers
• Vacuum entire floor
• The floor was sectioned off into 12’ wide columns using berms
• These berms were created using an epoxy/silica mortar
• All of the floors to receive the deep fill were primed using a 100% solids epoxy
• All areas that were severely broken were pre-filled using an epoxy/silica mortar
• Following the pre-fill, NFW installed over 10 tons of epoxy/silica mortar to ensure the floor would be flat
• Once the floor had time to cure, all areas were prepared using an industrial floor grinder
• This process removed any trowel marks that had been left behind
• Vacuum entire floor
• Install a thixotropic epoxy coat, allowing the material to penetrate only enough to create an adhesive bond
• Install a high-performance topcoat to areas respectively.

Conclusion:

Working alongside an entire contractor group, New England Floor & Wall was able to finish this project on schedule. Shown in the before and after pictures, the transformation of this project has been tremendous!

Decorative Concrete Flooring Case Study: Hilliard’s Chocolates in North Easton, MA

Customer Name: Hilliard’s Chocolates

Customer Location: North Easton, MA

Customer Needs: A decorative floor finish in the back of the house, and a durable floor that can stand up to the rigors of chocolate manufacturing

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Headquartered in North Easton Massachusetts, Hilliard’s Chocolates had been creating their exquisite candy in the same “Kitch-In-Vue Candy Store” that they had been using since 1950. As the need for space increased, they had commissioned a new facility to be built on the property. After meeting with the contractor, New England Floor & Wall and Hilliard’s’ agreed upon two separate systems; a decorative flake finish flooring system for the back of the house, and a ¼” epoxy resurfacer for the manufacturing area, with the caveat being that the entire floor would be installed over plywood.

Scope of Work: 

• All plywood areas were prepared using swing sanders and 36 grit sandpaper
• Vacuum entire floor
• Fill all plywood seams using an epoxy/amorphous silica blend
• Fiberglass over all plywood seams, increasing the structural integrity at all terminations
• Install patches created by epoxy mortar
• Install zinc strip to termination areas
• Install various integral cove base to eliminate the fear of water traveling
• Install ¼” epoxy mortar resurfacer system in manufacturing area- this product is one of the most durable on the market and is easy to clean and sanitize
• Install decorative flake flooring system in the back of house area, allowing for a slip-resistant floor that can stand the rigors of chocolate making while still being an aesthetically pleasing design
• Install a high-performance topcoat to both areas respectively.

 

Conclusion:

Working alongside an entire contractor group, New England Floor & Wall was able to finish this project on schedule. Shown in the before and after pictures, the transformation of this project has been tremendous!

Leicester Public Library Renovation: Mosaic Terrazzo Restoration & Epoxy Terrazzo Installation

Leicester Public Library Renovation: Mosaic Terrazzo Restoration, Repair, Deep Filling, and  Epoxy Terrazzo Installation & Polishing

An “original to the building” mosaic terrazzo floor had been discovered under a rug that was torn up during the demolition phase of the Leicester Public Library Renovation in Leicester, Massachusetts. The floor had some major cracks, deep penetrations, elevation issues, remaining layers of rug mastic contaminating grout lines as well as still adhered to large areas of the floor, and also had cementitious areas within the floor that built-in bookcases had been installed on that were in poor condition (shown below).

 

 

 

 

 

 

 

 

 

 

New England Floor & Wall was contacted to meet with the Architect Charlie Van Voorhis of DVV Architects to see if the floor could be restored. A small mock-up was performed to show what the floor would look like restored (shown below).

It was decided to come up with an epoxy terrazzo mix to infill the cementitious areas using Red aggregates. A sample composed of Red Cedar aggregate blend, silica sand, and a custom mixed General Polymers color was chosen for the terrazzo installation. The Infill areas were cut and chipped out, and deep filled with epoxy mortar to a depth of 3/8″ in preparation for the epoxy terrazzo. The next day the epoxy terrazzo was installed. The following day the infills were rough ground and a grout coat of resin was applied to fill any pinholes (shown below).

After allowing the grout coat to cure, the epoxy terrazzo was ground with 30/40 metals to full aggregate exposure. These areas were then ready to be restored and polished with the rest of the floor (shown below).

The floor was then ground and honed with a 6 step process using progressively finer grits of diamond tooling. A final pass was made using a Marble polishing compound and polishing pad. The floor was then cleaned thoroughly, sealed with a Stain Protector, and given a Final Burnish to “pop’ a mirror finish on the floor.

Resinous Flooring Montauk New York: Atlantic Terrace Motel Case Study

Customer Name: Atlantic Terrace Motel

Location: Montauk, New York

Flooring Needs: A metallic floor finish throughout the rooms and hallways

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Once a prime tourist destination located directly on the ocean, this motel was in dire need of a facelift. Full demolition of the existing finishes had occurred, only leaving a bare skeleton to work with. Existing floors were a composed of pre-cast concrete slabs, which had been hidden under the carpet until the demo. To reduce the risk of vapor transmission in close proximity to the ocean, New England Floor & Wall recommended the addition of a moisture barrier. Once a game plan was made, NFW began installing using the following scope:

Scope of Work for Resinous Flooring:

• Finish demolition of existing flooring
• Diamond grind entire floor with an industrial floor grinder
• Fiberglass over existing pre-cast concrete seams to reduce the risk of failure. This type of foundation has a tendency to expand, contract, as well as travel with the season changes
• Install patches created by epoxy mortar to ensure a flat floor
• Make “key-way” cuts in the doorways to help lock in the flooring system
• Install a resinous moisture barrier to help reduce the risk of vapor transmission
• Install a unique, reflective, high-performance resinous flooring system- this product has excellent stain resistance, chemical resistance, impact resistance, and slip resistance; it also creates a modern look, with a unique finish that a business can take pride in for years to come
• Install a high-performance urethane topcoat to the entire area to create a seamless look

Conclusion:

Tasked with a momentous project, New England Floor & Wall was able to finish this phase to meet the schedule set by the investment firm. With a 21^st century facelift, Atlantic Terrace Motel will be able to proudly show off this property for years to come.

Concrete Flooring Case Study: Decorative Resin Floors for Randolph Products

Customer Name: Randolph Products

Location: Chicopee, Massachusetts: Just outside of Springfield, MA

Needs: A decorative, yet durable, flooring system that hide tile grout lines

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The customer had acquired the facility from existing coatings manufacturer BASF and relocated in 2003 to support their growth in military, general industrial and conductive coatings business segments. Throughout the last decade, they have been completing major upgrades to their facility to ensure that they can compete with the growth in this industry. New England Floor & Wall was tasked with the job of providing a seamless floor directly over existing quarry tile.

Scope of Work:

• Diamond grind entire floor with industrial floor grinder
• Chip out existing tile surrounding drains and create a slope to drain that is flush in the finish flooring system
• Eliminate the majority of existing tile grout lines by flooding with an epoxy primer coat that has been mixed with silica sands
• Make feather edged cuts at termination lines to ensure floor has a clean termination
• Diamond grind entire floor to smooth and knock down excessive aggregate
• Use an epoxy impregnated with amorphous silica to patch any grout lines that remain
• Install a decorative flake high performance resinous flooring system- this product has excellent stain resistance, chemical resistance, impact resistance, and slip resistance; it also creates a uniform finish that a business can take pride in for years to come
• All flakes are knocked down with a steel trowel to
• Install a high performance polyurethane topcoat to the entire area to finish this beautiful seamless flooring system

 

Conclusion:

Working alongside an entire contractor group, New England Floor & Wall was able to completely eliminate the unsightly grout lines to complete this decorative flooring system according to the schedule laid out originally. Given the proper steps, these dated tile floors can be brought into the 21^st century with these durable floors that are also backed by manufacturers’ warranties.