Manchester Engineering Campus

Our team was tasked with installing a robust screed solution capable of withstanding significant site demands. We laid 25,000m² of 100mm Heavy Duty K Screed across multiple levels. This high-performance screed was installed over 100mm of Dow Floormate 700a extruded foam polystyrene board, specifically chosen to provide both thermal performance and structural strength.

Precision Installation to Support Infrastructure

The screed installation was designed to accommodate critical infrastructure needs. It incorporated service trunking and cabling within the build-up, effectively eliminating the need for surface-mounted equipment and providing a clean, efficient solution for housing essential services. This approach not only streamlined the installation process but also contributed to a safer, more functional environment within the campus.

Durability Under Rigorous Conditions

Given the early installation in the construction programme, the Heavy Duty K Screed and insulation needed to withstand extensive site trafficking for 12 to 18 months before the application of the final floor finishes. Throughout this period, the screed was subject to heavy vehicular machinery and typical site conditions. Despite these challenges, our expertly installed screed maintained its integrity and performance, ensuring a stable and reliable foundation for the subsequent flooring installations.

By delivering a screed solution that combined strength, durability, and thermal efficiency, we helped set the groundwork for a high-performance, long-lasting flooring system that meets the demands of this cutting-edge educational facility.

This robust system was chosen for its speed of installation, exceptional durability, seamless finish, and ability to withstand heavy foot traffic, making it the ideal choice for a bustling educational and research environment.

Why Power-Trowelled Resin?

Power-trowelled resin systems are renowned for their strength and longevity, offering a flawless surface that’s both functional and aesthetically pleasing. The mechanical rotary blade trowelling process ensures that the resin is evenly distributed and compacted, resulting in a smooth, dense finish that’s resistant to wear, impact, and chemical spills—perfect for the high demands of a cutting-edge engineering campus.

The Installation Process

The installation required precision and expertise. Our team meticulously prepared the substrate to ensure optimal adhesion and performance. Using advanced power-trowelling equipment, the resin was expertly applied and smoothed.

Versatility and Performance

This type of resin flooring is commonly used in large stadiums due to its ability to handle significant loads and intense usage, making it an excellent fit for the expansive and heavily trafficked areas of the Manchester Engineering Campus. The seamless finish not only enhances the visual appeal but also simplifies maintenance, ensuring that the floors remain pristine with minimal effort.

A Sustainable Choice

In line with our commitment to sustainability, the resin system we used has low VOC emissions and a long lifecycle that reduces the need for frequent replacements. This aligns perfectly with the project’s goals of creating a sustainable and future-proofed facility.

As part of our comprehensive work on this project, we were entrusted with the installation of mechanical expansion joints, a critical component in ensuring the structural integrity and longevity of the building. These joints play a vital role in accommodating the natural movements of the building, which can be caused by thermal changes, ground settlement, or other dynamic factors.

The Installation Process

Our team approached the installation with precision and care, ensuring that the expansion joints were integrated effectively into the building’s structure. Each joint was carefully placed to allow for the expected range of movement while maintaining the building’s strength and appearance. The installation process required close collaboration with other trades to ensure that the joints aligned perfectly with the overall construction plan.

Ensuring Longevity and Safety

By installing these mechanical expansion joints, Active Flooring Solutions has helped to future-proof the Manchester Engineering Campus against the stresses of natural movement. This proactive measure not only safeguards the building’s physical integrity but also ensures the safety and comfort of its occupants for years to come.

As part of the commitment to preserving the historical integrity of the Oddfellows Hall, a grade II listed building, we undertook the careful restoration of its timber flooring. This project required a delicate balance of craftsmanship and attention to detail, ensuring that the restored areas seamlessly blended with the building’s original features.

Reclaimed Timber: Matching the Parquet

The restoration process began with sourcing reclaimed timber that perfectly matched the existing parquet blocks in both size and appearance. These blocks were carefully selected to ensure they harmonized with the original wood, maintaining the authentic look and feel of the dining area and a section on Level 1.

Herringbone Pattern Installation

The existing parquet, laid in a classic herringbone pattern, was first meticulously sanded down to prepare the surface for the new blocks. The reclaimed blocks were then expertly installed, positioned directly against the existing parquet to ensure a flawless transition between the old and new sections.

Craftsmanship in Detail

To achieve a seamless finish, the team used a time-honoured technique of mixing sawdust from the sanding process with a sealant to create a custom filler. This filler was carefully scattered across the newly installed blocks to fill any gaps.

Design Features

In keeping with the original design, a 2-block border was installed around the perimeter of the area, with a 2-block mid-centre feature. These design elements were faithfully recreated to match the historical aesthetics of the space.

Finishing Touches

To complete the restoration, two coats of high-quality sealant were applied. This not only enhanced the natural beauty of the timber but also provided a durable finish that will protect the flooring for years to come.

To maintain the pristine condition of the Engineering Campus and protect its high-quality flooring from daily wear and tear, we installed premium aluminium entrance matting at key entry points throughout the building. This matting solution is designed to handle the heavy foot traffic typical of a bustling educational environment, effectively capturing and containing dirt and moisture before it can spread throughout the facility.

Keeping the Campus Clean and Protected

The aluminium entrance matting was strategically placed at all major entrances, ensuring that every person entering the building passes over the mats, leaving behind dirt and moisture. This proactive measure significantly reduces the amount of debris tracked inside, helping to keep the floors beyond the matwell clean and protected.

Easy Maintenance and Long-Lasting Performance

In addition to its exceptional cleaning capabilities, the matting is designed with ease of maintenance in mind. The durable aluminium construction and high-quality carpet inserts are easy to clean, ensuring that the mats continue to perform at their best with minimal upkeep. This not only extends the lifespan of the matting but also contributes to the overall cleanliness and appearance of the campus.

A Sustainable Choice

The aluminium entrance matting is not only a practical solution but also an environmentally conscious one. Its long-lasting design reduces the need for frequent replacements, aligning with the campus’s commitment to sustainability.

We were tasked with installing stunning timber staircases that not only serve an important functional purpose but also stand out as showcase features within the building’s design. These staircases seamlessly blend aesthetic appeal with durability, becoming a central element of the campus’s architectural identity.

Precision Craftsmanship with Recessed Nosings

One of the key design features of these staircases was the incorporation of recessed nosings, which sit flush with the timber surface. This design choice required exceptional precision and attention to detail during installation to ensure a seamless, smooth finish. Our team meticulously crafted each step, ensuring that the recessed nosings were perfectly aligned and integrated into the timber, enhancing both the safety and elegance of the staircases.

Solutions for Perfect Alignment

During the installation, we encountered varying subfloor levels that could have impacted the overall finish and functionality of the staircases. Rather than seeing this as a setback, our team proactively addressed the challenge by implementing precise levelling techniques to ensure a stable and even foundation for the timber steps. By carefully correcting the subfloor levels, we guaranteed that each staircase maintained its sleek appearance and provided a comfortable, safe ascent and descent for all users.

Delivering a Showcase Feature

The completed timber staircases are not just practical elements within the Manchester Engineering Campus but also striking visual features that complement the building’s modern, innovative design. The combination of high-quality materials, skilled craftsmanship, and thoughtful design has resulted in staircases that enhance the overall ambiance of the space, reflecting both the university’s commitment to excellence and our dedication to superior flooring solutions.

For the Manchester Engineering Campus (MECD), we installed a range of high-quality vinyl and carpet tiles designed to support the university’s innovative approach to learning. One of the key requirements for this project was to create versatile learning environments that seamlessly blended practical, hands-on activities with more traditional, written-based instruction.

Creating Innovative Learning Spaces

The MECD project called for lecture theatres and learning areas where students could not only discuss theoretical outcomes but also immediately put those ideas into practice. To support this dynamic educational approach, we selected floor coverings that provided both durability and flexibility. The combination of vinyl and carpet tiles allowed us to define different zones within the same space, enhancing functionality while maintaining a cohesive design aesthetic.

Durability and Purpose-Driven Design

Given the high-traffic nature of a university environment, all flooring materials had to be highly durable and fit for purpose. The vinyl flooring offered a robust, easy-to-clean surface ideal for practical, hands-on learning areas, while the carpet tiles provided comfort and acoustic benefits in spaces intended for discussion and reflection. Both finishes were carefully chosen to withstand the daily wear and tear of a busy campus, ensuring long-term performance and a professional appearance.

Precision in Level Planning

With a variety of different floor finishes being installed throughout the campus, precise level planning was essential to achieving a seamless transition between materials. Our team meticulously planned and executed the levelling process to ensure that all floor surfaces met perfectly, avoiding any trip hazards and maintaining a smooth, cohesive look across all learning spaces.

By focusing on both the aesthetic and functional aspects of the flooring, we were able to contribute to the creation of innovative, adaptable learning environments that reflect the university’s commitment to providing a world-class educational experience.