Premfloor (Southern) Ltd

Case Study: LEGO® Store, Leicester Square

Lego Resin Terrazzo Floor in Leicester Square, before and after

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

Close up of bespoke terrazzo floor box in Lego yellow

Panoramic shot of polished resin terrazzo in LEGO® Store Silhouette of man grinding floor in LEGO® Store Premfloor operative grinding resin yellow terrazzo with htc floor grinder and ermator vacuum Premfloor operative cleaning floor at lego store Lego Store Leicester Square - Coming Soon Banner

Before - Screed Repairs & DPM


Sample Production

Matching the existing sample of terrazzo from Lego

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

Damaged sand/cement screed in need of repair

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

Steel staircase with empty landing prior to terrazzo

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

Setting out strips in three colours for resin terrazzo

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

Hand laying yellow epoxy resin terrazzo next to grey stripe

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

Grinding terrazzo in the Lego Store

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

Applying 3 colours of epoxy grout to the LEGO® floor

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

Grinding terrazzo in the LEGO® Store

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 the floor with a high speed cleaning machine

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.


Self-levelling cement screed (Mapei Ultratop) terrazo finished customised colour with aggregate of river stones (tbc). When dry, screed to be polished using different sizes of diamonds/phenolic tools, and to applyling appropriate resin sealers.

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