Case Study: LEGO® Store, Leicester Square
540m2 - 3 Colour Resin Terrazzo Floor in the heart of London
Description
After matching three tile samples, we were awarded the contract to source and install a hand-laid glass terrazzo in the Worlds biggest Lego store at Leicester Square, London. Conditions on this fast track installation for the Worlds largest toy-maker were testing, with minimal storage, only timed deliveries, and several trades vying for space at any one time.
Summary
Two Floors, Three Colours
In-Situ Epoxy Resin Terrazzo
Challenging Rapid Fit Out
Bespoke Floor Boxes
Mixture of Day & Night Shifts
Dates: Sept - Oct 2016
Before - Screed Repairs & DPM
Sample Production
Client provided 3 tiles which they wanted replicating. Three weeks were spent producing around 50 samples until we could not improve the match. The colour-match was required to maintain corporate identity also applying to Desks, Counters and decoration.
Repairing Screed
Heavy duty traffic including forklifts and scissor lifts caused severe damage to the sand-cement screed onto which the terrazzo was to be laid. It was repaired using epoxy resin screeds and fibre bandages set into a penetrating pure epoxy resin flood-coat.
DPM
Prior to starting Premfloor conducted thorough site-wide moisture tests. It was agreed with the client that a DPM would be required before installing the epoxy terrazzo. Screeds and joints were bandaged, repaired and injected before the resin DPM was applied
During - Resin Terrazzo Installation
Setting Out Borders
Working from client drawings, metal divider strips were applied. The design called for dark grey borders with light grey and yellow fields on either side.
Resin Terrazzo In-Situ
Firstly, the dark grey borders were laid, to form the perimeter for both the yellow and light grey fields. All the poured terrazzo was hand-laid, and on average left approximately 2mm above finished floor level.
Grinding
Three-phase floor grinders were necessary to ensure compliance with the program. Excellent dust control was evident to comply with the quoted RAMS. The upstairs area was around 300m2 with 3 colours and required 3 days of careful grinding.
Grouting
Each colour of floor was grouted in a liquid colour-matched epoxy resin and marble dust. It was trowelled across the floor filling all pin-holes, and left around 1mm depth on the floor. The high internal temperatures during this phase necessitated the use of large air-movers to extend grout pot-life.
Polishing & Sealing
Following several polishing stages, we sealed with multiple layers of sealer, finishing with a light-stable polyurathane. This offered both UV and chemical resistance, and colour enhancement.
Buffing
Buffing was carried out with a high speed burnisher, armed with special pads. Reflection of the lighting modules can clearly be seen in the floor.
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