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Ferrari Workshop

Tiling installation in an operational workshop Top speed to the first authorised Ferrari workshop in Germany

  • Building Type: Commercial Construction
  • Pad: Natural Stone
  • Solution: Restoration of Old Subfloors
  • Brand: Codex
  • City: 83000
  • Country: International

At the end of November, the first authorised Ferrari and Maserati workshop in Germany, meeting all the corporate requirements of the luxury sports-car manufacturer and located in the Bavarian town of Irschenberg near lake Chiemsee, enters the home stretch. Authorised workshops must, among other things, undertake warranty services and repairs and must meet quite strict design criteria with regard to the premises. For example, apart from cabinets in specific blue and grey lifting-ramps, Ferrari requires that all ceramic flooring in all workshops must be identical in make, size and colour. The workshop looks after "Ferrari Challenge" customers from Chiemgau to Munich and also in Monaco and Naples.

New tiles on old – fast renovation with minimum disruption
For the whole of the tiling work, Uzin brand products were used. Controller of the project was the main building contractor, Bernd Neubert in Munich, who gave the order to Uzin Utz AG because of his positive past experience.
The installation teams from specialist contractor, Gerhard Neumann in Glonn, and the sub-contractor, Tobias Duschl in Bad Feilenbach, had only two months to install the specified stoneware tiles - 200 x 200 x 12 mm R11 Asiago Workshop from Fiandre – in the fully operational workshop. A special feature was that the existing tiled floor was over-tiled since the vibration-based tiling provided a very sound substrate. The basic idea is to leave down the existing surface as far as possible and to work on top with special adhesives, separating systems and special mortars. This relies on the adhesive bond to the existing glazed and contaminated tiles and on thin, stress-relieving constructions.
However, specially tailored construction recommendations from codex and Uzin as well as well as constant supervision of the project provided the installers the assurance to give a good and quick response.

Vibration-based tiling is installed anywhere that floors will be subject to heavy wear, for example in workshops, fire-stations and supermarkets. The vibrated-based tiling system is installed bonded direct to the base slab or onto a thermal and acoustic membrane, or is laid over a floor heating system. The vibration-based tiling is laid onto the freshly applied mortar bed and, with the aid of a vibrating compactor they are bedded into the mortar. The same day, the surface can be grouted and cleaned.

The great challenge for the installers was to achieve a strong bond to the existing tiles that had to be sound and free from separating agents and contamination.

Renovation of the tiled areas
First, all hollow areas were drilled through to the substrate using a 20 mm diameter drill-bit and at 20 x 20 cm grid centres. Then the drill-holes and any cracks were cleaned out using a high-performance industrial vacuum cleaner.

Preparatory work
As a filler the installation tam used the two-component repair resin, KR 416 from Uzin – a low viscosity, multipurpose acrylic resin for strong resin-bonding of joints and cracks. The areas wetted with resin, whilst still fresh, were scattered with UZIN Quartz Sand 0.8, a fire-dried, grade 0.3-0.8 sand, in order to guarantee a good key for the cement-based levelling compound.
Before tiles could be laid on tiles, the old ceramic flooring had to be thoroughly cleaned. The installation team decided on the intensive cleaner, Uzin RG 194, a solvent-free cleaning concentrate for dilution with water as a cleaning agent for old coverings and contaminated surfaces. After 20 minutes, the surfaces were thoroughly rinsed with clean water.
 
Installing the ceramics
The base tiles were primed with the carbon primer PE 370 from codex, applied by roller with a consumption of 150 to 200 g/m². With PE 370, carbon additives, in combination with other fillers, are added to a fibre-reinforced primer. This results in a rapid drying of the primer – with no tacky surface – and therefore a fast application.
After a drying time of approx. 25 minutes, any minor unevenness was smoothed over with the rapid setting, plasticised and free-flowing thin-bed mortar, Power Fluxx Turbo from codex. Then, the installers laid the fine stoneware tiles specified by Ferrari, Asiago Workshop from the Italian manufacturer Graniti Fiandre, using the Power Fluxx Turbo that is offered especially by codex for ceramic flooring due to its god flow properties. The mortar was mixed by the tiler with 5% codex Power-Mix additive, according to powder quantity, to form a high quality flex-mortar with excellent adhesion and deflection properties. It is especially suitable for heavy-wear domestic and commercial areas, as well as in industrial and heavy-load areas in both interior and exterior locations.

Grouting
Finally, the various movement joints were formed in the flooring construction: above existing structural joints in the same place and the same width, as bay-joints with a width of 8 – 10 mm and as edge-joints against adjoining structures and solid fixtures so that a movement of at least 5 mm was allowed.
With the movement joints, the installers divided the floor construction across its entire width. They grouted the joints using the two-component epoxy-resin grout mortar, Epo Tix from codex. It meets the highest demands for resistance to chemicals, aggressive liquids, oils and fats.
The movement-, bay- and connection- joints were filled with the permanently flexible, ready-to-use and rapid setting silicone mastic sealant, codex D 80.

Information about the installation contractor, Gerhard Neumann in the Bavarian town of Glonn
For the Ferrari and Maserati workshop in Irschenberg, two one-man contractors came together to form one working company. In charge was the tiling expert, Gerhard Neumann from Glonn. This master tiler and specialist undertakes both private and public contracts. Among his references are, for example, the Aying brewery – currently the most modern brewing facility in the world – and highly exclusive bathroom design work in private houses.