The Laser Screed Flooring, following the FM2-TR 34 4th Edition, represents a pioneering excellence achievement in the Green Field Project undertaken by Coca-Cola (Moon Beverages Ltd.) in Hapur, Uttar Pradesh.

Coca-Cola, the global beverage icon renowned for its commitment to quality and innovation, has once again raised the bar in its latest venture—a groundbreaking green field project in Hapur, Uttar Pradesh. This ambitious undertaking aimed to establish a state-of-the-art manufacturing facility that adhered to global standards, and at its core, lay the unwavering commitment to excellence.

In this remarkable journey, Zenith Flooring Services took on the mantle of transforming Coca-Cola’s vision into a concrete reality. Employing cutting-edge technology, including the state-of-the-art Laser Screed® machine S-158 C from Somero Enterprises® USA, we laid down M30 Grade RMC, covering a staggering 900 to 1200 square meters per day and, ultimately, 25,000 square meters in total. To ensure precision and quality, we employed imported flattening tools such as bump cutters, highway straightedges, power floaters, and ride-on trowels, delivering a flawless FM-2 surface finish as per TR-34 standards. The following day, the floor was meticulously sawn into panels on a 4.5- to 5.5-meter grid, relieving any drying shrinkage stresses. The flooring construction featured a single layer of mesh (8 mm dia., 200 mm C/C spacing) with a 50mm cover block from the bottom of the 150 mm thick grade slab, ensuring structural integrity and durability. Throughout the project, stringent quality checks were conducted to guarantee compliance with global FM2 standards from “TR-34 4th Edition, by The Concrete Society UK”.

Over the extensive 25,000-square-meter area, we (Zenith Flooring Services) executed a meticulous 5-step concrete polishing process.

Surface Refinement: The process commenced with precision grinding using planetary rotation 3-head grinders on the concrete surface, opening its pores, and erasing minor blemishes or stains. Grinding with a 60/100 and 200-grit resin bond delivered an initial phase that removed imperfections and inconsistencies, creating a pristine canvas.

Enhancing Durability: A liquid densifier was uniformly applied during polishing, enhancing the concrete’s durability from within while simultaneously hardening and densifying it.

Honing the Surface: This crucial step further refined the surface, ensuring a smooth and level base. Polishing was executed using resin-bond 400 grit and subsequently with resin-bond 800 grit. The honing process not only enhanced the surface’s sheen but also prepared it for the final polishing stages.

Perfecting the Shine: The surface was finished with resin bond at 1500–3000 grit, depending on the desired sheen level. Multiple polishing steps were meticulously undertaken to achieve the desired gloss and finish. This process resulted in a surface that was not only dust-free and resistant to efflorescence but also boasted stain-resistant flooring with enhanced reflectivity and higher levels of slip resistance.

The benefits extended beyond aesthetics, with cost-effective ongoing maintenance, reduced tire abrasion, minimal disruption to operations, and no extensive cleanup, toxins, or hazards. In the end, Zenith Flooring Services not only completed the project but surpassed Coca-Cola’s expectations.

A collaborative triumph: Zenith Flooring Services and Coca-Cola

The partnership between Zenith Flooring Services and Coca-Cola culminated in an extraordinary floor, embodying the legacy of quality and innovation that Coca-Cola represents. By adhering to global standards, harnessing cutting-edge technology, and executing meticulous processes, we have ensured that Coca-Cola’s Hapur facility stands as an emblem of excellence in the industry.

We eagerly anticipate the opportunity to join you on your next project as we continue our journey towards excellence together.