Case Studies

Through our long service to the industry, we have catered to the needs of a range of industries. Our flooring systems are used widely in a variety of industries to protect concrete from the constant exposure to heavy traffic, whilst providing a chemically resistant surface which can be easily cleaned.

Gate Gourmet - Airline Catering Services - Mascot NSW

Gate Gourmet is the world's largest independant provider of catering and provisioning services for airlines and railroad.

The Mascot premises was in need of an upgrade, with much of the old vinyl and epoxy finishes worn and fatigued. The difficulty in the refurbishment process was that Gate Gourmet runs a 24 hour / 7 day operation, meaning we would have to carry out works in stages, with no production shutdown, whilst using low odour products and dust-less floor preparation methods. 

Profloor were contracted to carry out the replacement of 2 key process areas over two floor levels without shutting down, spanning over 1100m2.  

Profoor removed the existing vinyl an epoxy finishes in stages and carried out captive vacuum diamond grinding to expose the original concrete substrate, and installed a heavy duty 4mm self-levelling epoxy system to commercial preparation areas, and a heavy duty 6mm system to the dishwash areas.

Both areas had different anti-slip requirements, as the preparation kitchen was for dry processing, and the dishwash area was a wet process area. Profloor incorporated a fine anti-slip system to dry kitchen areas, meaing the system was easily mopped clean, whilst retaining an R10 slip rating, and the Dishwash area was installaed with a course anti-slip finish which achieved an R11 slip rating, as this area is hosed down regularly.

After many years of service since the instalation, the floors are still in perfect condition, and the client is very impressed with the durability, the safety, and the cleanliness of the epoxy floor finishes. 

Fosters Australia Ltd - Dangerous Goods Stores

Profloor have been contracted by Fosters Australia for many years on various production sites in NSW, providing quality  flooring solutions for a range of process areas in their alcoholic beverage manufacture facilities.

Profloor were approached during the design stages of a new dangerous goods store, which was due to be built later in the year. Profloor specified a heavy duty 6mm anti-slip epoxy finish, which had excellent resistance to the diluted chemicals that were being stored in these areas.

Asides from the heavy dutuy floor installation, the project also included the installation of epoxy coving at wall and floor junctions, the treatment of drainage channels, expansion joint treatment and the preparation and sealing of bunded containment walls, in the event of any small spills or leaks.

In true Fosters nature, the clients selected a blue colour to represent their company, and the anti-slip finish provided was R11, to comply with the current lgislative requirements.

The floor was installed to strict specification, with all the chemical resistance requirements fulfilled.

Fosters and Profloor have also minimised the risk of environmental impact by bunding and lining these areas with the highly chemical resistant epoxy, in the event of a tank leak or spill.

Toyota Workshop – Waitara NSW

An excellent example of the use of Epoxy flooring systems in an industrial environment is at Toyota, where their national specification requires the implementation of a high end epoxy finish to their workshop and parts areas.

Profloor Epoxy Systems were contracted to prepare the new concrete substrate and apply the specified floor finishes to 1400m² of floor area, in various colours to distinguish service bays, wash bays and detailing areas from the main driveway.

The system applied has to withstand constant vehicular traffic, whilst also providing high impact and chemical resistance. The project took just 7 days to complete, with outstanding results. The pictures show various stages of the project such as floor preparation, application of the coatings, and the finished product.

The project was completed to strict product specifications, within the original budget, and completed within the tight construction timeline. 

Coles Supermarket - Gungahlin ACT   (Australia's Largest Coles Store)

Profloor Epoxy Systems have been involved in retail projects for almost two decades, and have completed hundreds of retail projects throughout the years including many major retailers such as  Coles, Woolworths, IGA, Aldi & Franklins.

Coles recently specified the use of Heavy Duty 6mm Polyurethane Cement flooring systems for their various food preparation departments including the Deli, Seafood, Meat, Bakery, Produce & Coolroom areas in their new Large Concept store in Gungahlin ACT. 

Polyurethane Cement systems are extremely durable and resistant to a wide range of chemicals, fats and oils, however the most important characteristic is the service temperature range. Polyurethane Cements work in extreme tempratures, particularly heat, with a general range between -20 and +120 degrees, where standard flooring systems would fail.

The project included a wide range of finishes that Profloor supply and apply, including compatible Epoxy based waterproofing membrane to all food preparation and coolroom areas, installation of a graded falls screed to floor wastes with epoxy mortar, the installation of the 6mm polyurethane cement flooring and coving systems, and sealing of Back of House concrete areas.

The 600m2 project was completed in short stages to accommodate the tight construction program, and each stage was handed over in record time, ensuring that Profloor did not affect any other finishing trades, and that the constuction team could hand over the store departments on time.

Together with Coles and their construction team, we have ensured that this new model store has increased its floor service life, by using correct application techniques from Profloor's professional team, and by incorporating high end products such as the polyurethane cement system.

Hungry Jacks - Glendenning NSW

Recently Profloor was approached by Hungry Jacks Management about a nuisance floor which has been a problem for many years. The old epoxy floor was worn and torn to the point of disrepair, and when they called in another contractor to install a new floor, they failed. This excercise cost one weeks closure, and they had an unacceptable floor finish to show for it.

To make matters more complicating, the restaurant was built on a BP petroleum site, where strict safety measures are mandatory.

Profloor were called in to manage the flooring situation, and had specified the use of fast curing MMA flooring to resurface the whole floor area, to ensure there would no longer be any store closure. Profloor quickly had their employees inducted under the "Australian Petroleum Industry" to enable works on petroleum sites

The floors were captive vacuum diamond ground to remove all of the high spots and imperfections in the previous epoxy finish, and prepare it for the subsequent floor finish. The floors were trowelled at a thickness of 5mm, to provide long life wear and tear, and all coves were prepared and sealed to match the specified floor colour.

Our clients were extremely happy with the finish, and with the fact that they now have an Australian standards approved floor finish, and no longer have to worry about loss of trade due to constant flooring issues.

Woolworths Distribution Centre - NSW

Distribution warehouses are constantly punished by heavy fork lifts and general traffic. Profloor have for long been in the business of providing long lasting flooring solutions for harsh work environments.

Profloor were approached to refurbish some 350m2 of existing workshop area, where fork trucks are serviced and maintained within their distribution centre on a regular basis. Heavy oil impregnation and abrasion damage was evident in the existing concrete floor, and was becoming a serious safety issue.

The floors were treated using an aggressive captive vacuum diamond preparation method to ensure no dust would affect Woolworths employees whilst providing a good mechanical key, and our Non-Toxic 6mm trowelled "Profloor EP3" Epoxy floor system was installed to the whole area. The project was staged over 3 weekends upon request by the client, to ensure minimal disruption to the daily distribution of supermarket goods to the Woolworths chain of stores Australia wide.

The new "Profloor EP3" system is easy to maintain, provides optimal slip resistance and provides a Brighter / Safer work environment. In todays market, Safety is of utmost importance, and in this instance, the application of our "Profloor EP3" system demonstrates that Woolworths are very dedicated to their "Destination Zero" Safety Policy, and strive to implement various systems to achieve a safe work environment.