Case Study: Resin Terrazzo in Theatre Toilets

Sample Creation

After several attempts we finally created an acceptable match for the tile, as shown above. The blend of aggregates centres around various marbles, along with other selected ingredients.

Existing Toilets

The existing toilets had been down for many years. Given the challenges of working in Theatre fit-outs are typically carried out every 10 years. Premfloor seamless resin terrazzo offers an attractive, long term, almost maintenance-free surface.

Strip Out

Our starting point was floor tiles, wall tiles, fixtures & fittings removed. Challenges we face include going round drainage pipes, holes & channels in the floor from existing drainage etc, and varying levels previously addressed with dollops of tile adhesive.

Removing Rotten Wood

The old theatre floors are a mixture of old terrazzo, rotten wood, newer chipboard, ply wood and concrete. Where the wood is rotten or damp, we request it removed and replaced with a marine grade ply properly fixed. All substrates must be solid, dry and given a rough key.

Surface Preparation

We pcd & diamond grind through adhesive, contaminants, latex etc. It's always our preference to affix resin terrazzo to the lowest most secure substrate possible, often bonding to an epoxy screed. We have limited space and power (110v) on site so larger machines are not always practical, also having to be transported up to 7 flights of stairs and stored away every day in the basement.

Epoxy Mortar & Screed

Where required, we use an epoxy screed to raise levels, repair holes, scrim cracks, reinforce edges and plug gaps to provide a solid substrate. Epoxy screed results in an extremley solid substrate which can be quickly adhered to due to no presence of moisture. We opt for a sand rich screed, topping up the following day to ensure full strength.

Lay Terrazzo Screed

Using trowels we hand lay the screed to approximatley 10-14mm. The pot life on epoxy screed is around 30 minutes in this theatre. Each mix is 4 parts (resin, hardener, fine aggregates, coarse aggregates), we usually complete 4-5 mixes per hour due to the space and working time restrictions. In the photo above we are installing terrazzo onto a flexible membrane we applied to a wooden floor (in sweltering summer temperature)

Grind & Polish

We start grinding the freshly laid epoxy usually between 18-30 hours after it's been laid depending on time of year (the epoxy must be properly cured.) We utilise our HTC 420 for grinding smaller areas and carrying up flights of stairs. This is due to lack of an elevator and three phase power available on site. The HTC 420 lets us grind the floor flat with dust control measures in place.

Seal

Once we've ground, grouted and polished the terrazzo, we then move onto sealing the floor. The floor must be cleaned thoroughly, mopping and cleaning any residue from the polishing processes, or removing any marks caused by foot traffic. Sealer is applied with a short pile roller or applicator and we apply three coats.

Precast Terrazzo Stairs

Working through the 6 sets of toilets in the theatre, two of the female toilets feature pre-cast stairs we supplied & installed with #51 ivory quantum sf225r nosings [link].

After Sealing

The above photo is taken after applying multiple coats of sealer. We didn't want a wet look floor so after the sealer has dried it lightens and improves abrasion & stain resistance.

After Fit-Out

Our client is a high end specialist fit-out contractor, their work is always completed to an extremley high standard, transforming every set of toilets after our floor was finished.

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