Ucrete Installation – Booths Supermarket, Ulverston

The food preparation areas at Booths Supermarket in Ulverston are constantly in use. Floors in these environments are exposed to heavy foot traffic, regular cleaning regimes and daily operational pressures. Any refurbishment work has to be carried out carefully to ensure the finished surface is durable, hygienic and capable of withstanding the demands of a busy supermarket environment.

H³ Construct were appointed to replace a failed vinyl flooring system and install a new industrial-grade floor designed for long-term performance. Rather than simply patching over the existing surface, the works involved removing the failing Polyflor finish, preparing the concrete substrate correctly and installing a heavy-duty Ucrete polyurethane concrete system that would provide a robust, seamless and hygienic flooring solution for years to come.

Before the new flooring system could be installed, the existing surface had to be completely removed and the concrete substrate properly prepared. The floor was still carrying the remains of a failed Polyflor vinyl system, along with residual adhesives and surface contaminants that would prevent any new resin system bonding correctly.

The existing finish was stripped back and the slab mechanically diamond ground to remove adhesive residues, laitance and any surface contamination that had built up over time. This process exposed clean, sound concrete and created the mechanical profile required for a high-performance polyurethane concrete system to bond effectively to the substrate.

Additional preparation works were carried out to ensure the new floor could integrate correctly with the surrounding structure. Channels were carefully cut into the slab to allow the Ucrete system to be securely tied into the floor construction, preventing edge failure and ensuring long-term durability under traffic and cleaning regimes.

Perimeter details were also prepared to allow hygienic coving to be formed, creating a seamless transition between floor and wall. This eliminates dirt traps and allows the floor to be properly cleaned and maintained in a food preparation environment.

Only once the substrate had been fully prepared and stabilised was the surface primed and ready for installation of the new Ucrete system. The objective was not simply to install a new finish, but to ensure the underlying concrete was correctly prepared so the floor could perform reliably under the demands of a working supermarket environment.

With the substrate fully prepared, the concrete was primed to regulate absorption and ensure a consistent bond between the slab and the new flooring system. The primer acts as the intermediary layer between concrete and polyurethane concrete, sealing the surface and stabilising the substrate before the main system is installed.

Applied evenly across the prepared slab, the primer penetrates into the open pores created during the mechanical preparation process. This locks into the concrete surface and creates a stable bonding interface capable of supporting the weight and mechanical loading that the finished floor will experience in service.

The aim at this stage was not simply to coat the concrete, but to control the way the Ucrete system interacts with the substrate beneath it. By sealing the slab and creating a uniform bonding condition across the floor, the primer ensures that the system cures consistently and performs as intended under heavy use.

Only once the primer had fully bonded to the prepared concrete was the surface ready to receive the Ucrete installation. This step ensures the floor becomes part of the structure itself, rather than a layer sitting on top of it.

With the primed substrate ready, the Ucrete UD200 system was installed across the prepared floor area. The material was mixed and placed onto the slab before being spread and compacted to the specified thickness, forming a dense polyurethane concrete layer designed for heavy-duty service conditions.

Unlike conventional resin coatings, Ucrete is a full-bodied flooring system. It does not simply sit on the surface of the concrete but forms a robust polyurethane concrete layer that integrates with the prepared substrate beneath. This construction gives the floor exceptional compressive strength and resistance to mechanical impact, thermal shock and aggressive cleaning regimes.

The material was applied evenly across the floor and compacted to achieve a consistent thickness and surface finish. Care was taken to ensure the system was properly tied into the previously prepared channels within the slab so that the edges of the floor remained secure under long-term operational loading.

Once cured, the finished surface provided a dense, chemically resistant and highly durable floor capable of performing reliably within a busy supermarket food preparation environment. The result was not simply a replacement finish, but a robust flooring system designed to withstand daily operational demands.

The junction between floor and wall is one of the most vulnerable areas in food preparation environments. Sharp corners trap moisture, debris and cleaning chemicals, making them difficult to maintain and allowing contamination to build over time. In high-hygiene facilities these details must be eliminated rather than simply sealed.

To address this, hygienic coving was formed around the perimeter using Sika Ucrete RG, a polyurethane concrete render specifically designed for coving and vertical detailing within Ucrete flooring systems. The material was built up at the wall junction and shaped to create a smooth, continuous radius that links the horizontal floor surface with the vertical wall.

Using the same polyurethane concrete technology ensures the coving performs in exactly the same way as the floor. It delivers high mechanical strength, resistance to aggressive cleaning chemicals and durability under constant washdown conditions. The material is impermeable to liquids and does not support bacterial or mould growth, making it suitable for demanding food and beverage environments.  

The finished detail creates a seamless transition that allows the floor to be cleaned effectively while protecting the floor-wall junction from impact, moisture ingress and long-term deterioration.

With the Ucrete system fully installed and cured, the floor formed a seamless, heavy-duty surface designed to withstand the operational demands of a working supermarket environment. The finished floor provides exceptional resistance to mechanical wear, aggressive cleaning chemicals and constant foot traffic while maintaining a dense, impermeable structure.

Particular attention was given to the perimeter details and thresholds to ensure the floor was fully integrated with the surrounding construction. Junctions were carefully sealed and mastic-filled where required, allowing controlled movement while maintaining a watertight finish.

The completed system delivers more than a clean appearance. It provides a durable, hygienic and easy-to-maintain surface capable of supporting daily operations while protecting the underlying concrete structure from moisture ingress, contamination and long-term deterioration.

The result is a floor built not just to perform today, but to remain reliable under continuous service for years to come.

The Flowerbowl

Total Area: 800m²

H³ Construct were appointed to deliver specialist flooring works at The Flowerbowl Entertainment Centre in Preston, focusing on the resurfacing of the curling rink slab. As a unique leisure venue and official training base for the GB Curling Team, the facility required a high-performance solution with minimal disruption and a flawless finish.

The selected system was Sikafloor® MultiDur WS-18, a water-based epoxy coating known for its low VOC emissions, excellent adhesion, and resistance to abrasion and chemicals. The system includes Sikafloor®-2510 W as both primer and topcoat, offering a seamless, semi-gloss finish ideal for interior use in sensitive environments like ice rinks.

Before our works could begin, the Flowerbowl team coordinated the controlled melt of the curling ice—a process that took four days to complete. Once the slab was exposed, our operatives carried out mechanical surface preparation via grinding, followed by industrial vacuum cleaning to ensure a clean, dust-free surface for application.

The Sikafloor® system was installed in accordance with manufacturer guidelines. A diluted primer coat was applied first to promote bond, followed by a full-strength topcoat to achieve the desired thickness and finish. The fast-curing properties of the product allowed for efficient installation and a quick return to service—critical for a venue regularly used by professional athletes and the public alike.

Our team coordinated closely with the venue throughout the works to maintain safety, cleanliness, and clear communication. The project was delivered to a high standard, on time, and with no disruption to the wider operations of the centre.

H³ were able to deliver a precise, high-quality flooring solution in a live, specialist environment—supporting elite sport while meeting the practical demands of a public facility.

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The project began with subfloor preparation. The existing substrate was cleaned, primed, and levelled using a cementitious smoothing compound to achieve a uniform surface with ≤3mm deviation over 2m. Special care was taken to manage ambient temperature and humidity levels during the conditioning and laying phase to avoid dimensional instability.

The Expona Flow vinyl was installed using Polyflor-approved pressure-sensitive adhesives, with the sheets conditioned on-site for 24 hours prior to laying. Each roll was cut, back-rolled, and slabbed to prevent curling and ensure accurate seam alignment. Where coved skirting was required, we used Ejecta cove formers and sit-on capping strips, adhering the vinyl with contact adhesive to create seamless, hospital-grade corner finishes.

Construction joints within the floor slab were treated with Gradus aluminium joint covers. These were installed to allow for minor movement while providing a flush, unobtrusive finish that didn’t compromise the studio’s clean aesthetic.

The works were completed outside of trading hours to avoid disruption, with the installation carried out in phases over five night shifts. All areas were handed over clean, sealed, and ready for immediate use, with clear care and maintenance guidance provided to the client.

The completed project has enhanced the functionality and visual appeal of the studio, with the flooring delivering both comfort and resilience under daily use. Feedback from the client has been highly positive, particularly in regard to the quality of finish and the attention to detail shown during installation.

St Davids Dewi Sant

H3 Construct was appointed to deliver extensive remedial works across two operational car parks at St David’s Shopping Centre in Cardiff, including the main multi-storey structure and the basement-level John Lewis facility. The scope included deck coating repairs, concrete and asphalt works, structural render replacement and water ingress investigation and rectification.

One of the primary challenges was maintaining safe, uninterrupted public access throughout the project. Specific working parameters were enforced, including weekday-only closures on designated levels and out-of-hours works in areas such as the John Lewis basement. All required phased coordination and close liaison with the Centre’s management team.

Deck coating repairs were carried out across multiple levels using a specification-compliant coating system from Sika. Works included substrate preparation via mechanical means, full assessment of the existing deck surfaces and detailed patch repairs totalling more than 80 separate locations. In the John Lewis car park, concrete repairs were also completed to columns and beam elements using BS EN 1504-compliant R4 repair mortars.

H3 Construct also managed specialist leak detection works following reports of water ingress into the level 7 lift lobby and stairwell. Testing revealed that failed seals in the level 8 lobby window frames and inadequate door thresholds were allowing water to track into lower levels. The remedial scope included sealant replacement, threshold adjustments and patch repair to water-damaged finishes.

Additionally, significant damage was identified to the insulated render system surrounding the staircore. Following destructive testing, H3 confirmed no moisture was present within the render, and full perimeter replacement of the lower 600mm section (96m²) was undertaken using mineral wool-backed, through-colour render to match the existing texture and finish.

Throughout the works, all health, safety and CDM responsibilities were managed by H3 Construct as Principal Contractor. The project was delivered under a JCT Minor Works Contract with Contractor’s Design, and included submission of warranties, repair records, and a full Health & Safety File on completion.

The scheme was completed on time, in compliance with the clients specific standards, and with no disruption to public operations — a result of clear planning, strong technical oversight and a proactive site team.

Q-Park The Light

Total Area: 3700m²

H³ Construct was appointed to carry out major refurbishment works at Q-Park The Light, a busy underground car park located in the centre of Leeds. The works were delivered over an 8-week period and were carefully planned to maintain car park operations throughout.

The scope of the project included over 250 m² of concrete repairs to the deck and soffit areas, the installation of galvanic anodes (C-Puck) for long-term corrosion control, and the full recoating of approximately 3,700 m² of the parking deck using the BASF Masterseal traffic-grade system. All areas were prepared via captive shot blasting, ensuring a clean, profiled substrate ready for primer and coating application.

One of the main challenges was the car park’s location and usage—it is fully underground and in constant use. A key requirement was to maintain a live traffic route throughout the works to provide continuous access to the lower levels. Our site team worked closely with Q-Park’s operations staff to phase the works in a way that allowed safe contractor access while keeping customer disruption to an absolute minimum.

The concrete repairs were carried out using rapid-cure, high-strength mortars to ensure fast turnaround and early overcoating. Galvanic C-Puck anodes were installed within the repair areas and to surrounding zones to mitigate further corrosion risk to the reinforcing steel. These were installed and tested in accordance with the manufacturer’s requirements and recorded for client handover.

The coating works included the application of a full BASF Masterseal system designed for traffic-grade use, offering chemical resistance, slip resistance, and durability in high-wear areas. The system was applied in multiple coats with strict environmental controls, ensuring cure times and bond strength met specification.

Close coordination and sequencing were essential to maintaining both safety and programme. The car park remained operational for the entire duration of the works, with clearly defined traffic routes, barriers, and signage used throughout. Regular updates were provided to Q-Park management and daily planning ensured all critical areas were handed back on time.

The project was delivered on schedule, to specification, and with positive feedback from the client and site users. The finished surface provides improved durability, a cleaner visual appearance, and long-term protection of the structure.