As a reliable supplier of high performance flooring systems, Sika recently scooped the contract for flooring Unilever’s new state-of-the-art ice cream factory at Lord’s View Industrial Park, Midrand. The first factory of its kind in Africa, it boasts the latest green technology including zero waste to landfill and the use of smart water efficiency technology. 

Engineers from Pharmadule, together with advice from Sika representative Chad Tosen, specified six Sika products for sealing, screeding and coating of the factory floor. All Sika products specified are approved for use in food processing plants, and boast multi-international endorsements. Industrial flooring specialist, Seal Con Systems was contracted for the 2600m2 project which included extensive grinding of the floors prior to application of the Sika products.

Cracks and voids in the floor were filled with Sikadur-52 ZA, a two-part, low viscosity injection liquid, based on high strength epoxy resins. Solvent-free and suitable for both dry and damp conditions, Sikadur-52 ZA provides good adhesion to concrete, mortar, stone, steel and wood. It provides shrinkage-free hardening and not only forms an effective barrier against water infiltration and corrosion-promoting media, but also structurally bonds concrete sections together. Since low temperatures do not affect its performance, Sikadur-52 ZA was ideal for this project, which took place during winter.

Floors were primed with Sikafloor-161, a two-part, solvent-free, low viscosity epoxy resin that is economical and easy to apply. Suitable for normal to strong absorbent surfaces, it provides excellent bond strength and short waiting times. The primer was overlaid with a 6mm coating of Sikafloor-21 N PurCem, (1100m2 beige, 1500m2 dark grey), a three-part, water-dispersed, medium to high strength, polyurethane modified cement and aggregate screed with self-smoothing properties. Its excellent flow characteristics allowed for easy application while its aesthetically pleasing smooth textured aggregate surface is easy to clean and provides medium slip resistance.

Since the factory was newly constructed, the large, obstacle-free, open floor area allowed for even quicker application of the already easy-to-use Sika products. Coving and detailing work was coated with Sikafloor-29 N PurCem, a three-part, water-dispersed, coloured polyurethane modified cement and aggregate mortar with a finely textured smooth aggregate appearance.

Both Sikafloor-21 N PurCem and Sikafloor-29 N PurCem possess a similar coefficient of thermal expansion to concrete while their bond strengths exceed the tensile strength of concrete. Both products are jointless, easily maintained and provide excellent resistance to chemical attack, abrasion and mechanical damage. They are non-taint, odourless, VOC free and fast-curing, allowing full service after only two days. Detailing areas coated with Sikafloor-29 N PurCem were subsequently sealed with Sikafloor-31 N PurCem, an economical three-part, solvent-free, high build, coloured polyurethane modified, cement and aggregate coating, offering the same high resistance to chemicals, abrasion and mechanical damage as the other PurCem products.

The floor was finally sealed with Sikaflex PRO-3 i-Cure, a one-part, moisture-curing, elastic joint sealant that incorporates Sika’s advanced i-Cure Technology. Designed to reduce emissions, i-Cure sealants and adhesives are solvent-free and totally odourless, thereby meeting the highest and increasingly stringent international emission standards. Sikaflex PRO-3 provides a movement capability of 25%, bubble-free curing and high mechanical and chemical resistance. This high performance, multi-purpose sealant is suitable for indoor and outdoor applications.

Since data shows that per capita, South Africans consume only one litre of ice cream per annum, compared to 15 litres per annum consumed by New Zealanders, Unilever is confident that its novel R600 million environmentally efficient factory has significant growth potential. This project was a perfect example of Sika’s state-of-the-art ‘green’ products enhancing a state-of-the-art green design.

For more information on Sika products and systems, visit www.sika.co.za