Interloop
Interloop Limited is one of the largest socks manufacturing companies in the world. It supplies socks and leggings to big retailers like Nike, Adidas, H&M, Puma, Levi’s, Reebok, and Target.
Project Requirements
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It’s beyond doubt that a manufacturing plant and industrial floor experiences damage over the years. With foot-traffic around-the-clock and heavy to medium-sized machinery, one cannot afford to have a floor buckle, crack or a slippery surface that can lead to safety concerns. A properly installed, durable floor system is an absolute need to keep the business operations running smoothly and productively. All these concerns need to be addressed in an economical manner keeping in mind a textile factory-like Interloop spans over large areas.
Hence, for the same reason, Interloop Limited hired Vertex Chemicals to provide seamless, easy to clean, chemical, and impact-resistant flooring for the stitching unit, that is not only attractive but dependable and slip-resistant for years to come.
Challenges & Solution
Keeping in mind the stringent requirements of Interloop’s stitching unit floor, Vertex Chemicals proposed its high-performing Polished Concrete, NeoCrete. We chose NeoCrete because of its tendency to transform a wide selection of concrete surfaces into smooth, highly resistant, and stunning glossy surfaces in the most cost-effective manner. The floor is not only water-resistant but is tough, easy to clean, anti-slip, and hygienic, making it above and beyond any conventional flooring system. Furthermore, keeping in mind the longevity requirement of the client, NeoCrete does not involve the application of a cosmetic or superficial layer but becomes an integral part of the concrete substrate itself. This ensures that the floor is exceptionally long-lasting.
The application of this floor was not a straight-forward task as the substrate had to be poured in relatively small panels measuring 8’x8’. Many of the panels were damaged and sagged from the use of heavy machinery. These faulty panels were removed and were filled with concrete, with added polycarboxylate admixture coupled with epoxy bonding agent M3EP to ensure a strong bond with old concrete. A large section of the joints between the panels was damaged and had to be repaired as well. Our application team cut approximately 5000 RFT joints open to ensure that V1/50 grout could be poured into the pockets to ensure longevity and high resistance. This was finally followed by repairing the surface with a rapid setting cementitious material, designed by our R&D, specifically for this project. All these meticulous repair jobs were only possible due to close liaison with our R&D and in-house application team to ensure that the complex project is delivered within time.
To install the floor, our team performed a step-by-step grinding and polishing process. First, the concrete substrate is ground with the most advanced industrial tools, and later hardeners and sealers were infused to level, polish, and seal the floor for the final look. In our product, it is not required to wax the floor to maintain the shine; simple damp mopping is enough to restore the gloss, making this a very easy to maintain the system.
The client was pleased with the final look of their stitching unit. They went hassle-free in terms of maintenance, cleanliness, and hygiene perspective, and to top it off, the floor gleamed all across the hall from one corner to another, giving it an exquisite feel. Most of all a seemingly impossible project was delivered well before the deadline.
In addition to admixtures, our team supplied several other materials throughout the course of the projects, as required to keep the pace of the project, working hand in hand with the client’s team.