Consistent use creates wear and tear so when the hangar floor at Anglo Aircraft, situated in OR Tambo Airport in Gauteng, became rutted and rough, a request for resurfacing was made. Anglo Aircraft appointed Permafloor, specialists in the protection and rehabilitation of concrete structures, and they requested that Sika specify their innovative epoxy products for the job.

Preparation of the 3000m2 substrate was achieved by means of porta blast cleaning using SPE shot blasting machines, followed by de-greasing of all oil-contaminated areas. Initially, moisture readings conducted on the floor were too high for the application of an epoxy floor.  As a solution, Sika altered the original product specification to SikaGard-720 EpoCem ZA a moisture barrier system which could be applied should moisture readings have remained too high after completion of the surface preparation. This three part, epoxy modified, cementitious, thixotropic, fine-textured mortar for leveling and finishing of concrete, mortar or stone surfaces was used primarily for its ability to prevent rising moisture but also for its excellent protection of concrete in aggressive environments, good chemical resistance, and its easy and fast application. It offers an excellent bond to green or hardened concrete whether damp or dry, allows minimum waiting time prior to the application of other Sika epoxy resin based products, and is the ideal preparation for smooth surface finishes.

Joint nosings were repaired by application of Sikadur-43 ZA (10 units) a solvent-free, three-component, repair and filling mortar based on a combination of epoxy resins and selected high strength aggregates. Providing rapid, shrinkage-free hardening and high mechanical strength, this trowelable mortar is suitable for both dry and damp surfaces with curing not being affected by high humidity. It also offers abrasion and impact resistance.

The substrate was then primed using 30 units of Sikafloor-156 ZA, a two-part, low viscosity, solvent-free epoxy resin primer, which provides good penetration ability and high bond strength to the substrate. This multi-purpose product, suitable for internal and external use, is easy to apply with short waiting times.

To ensure that the hangar floor was level, Sikafloor-261 ZA SS1 (118 units) was applied at 1mm thick as a leveling layer-scraper coat. Due to its low viscosity, this two-part, epoxy resin binder along with various filler components has the ability to produce highly filled self-smoothening and broadcast layers as well as textured layers, mortar screeds and sealer coats. The broadcast system is highly suitable for wet process areas such as abattoirs and dairies as well as in maintenance hangars, as its tight glossy surface is chemical resistant and slip-resistant.

Following application of the scraper coat, a two-coat high build layer was applied. All expansion joints were then resealed using Sikaflex PRO-3 WF, a moisture-curing, one-part elastic sealant based on polyurethane. With a movement capability of 25%, this multi-purpose product provides bubble-free curing, and very good mechanical and chemical resistance.

Finally, all demarcation lines were coated on the Hanger Floor, leaving a perfectly smooth, glossy and functional surface for the Anglo aircraft to be parked and stored.