When Saint Benedict Catholic Voluntary Academy in Derby required a flooring system for its new two-storey modular building, delivered by modular building specialist Algeco, Envira Floors Ltd turned to Bostik for technical support and a comprehensive product solution. The multi-million-pound project demanded a flooring approach that could address the unique challenges of modular construction whilst meeting the rigorous demands of an active educational environment. The new block brings together the academy’s science laboratories and teaching spaces, increasing the need for a safe, durable and easy-to-clean flooring solution.
JOINTS & MOISTURE MANAGEMENT
Modular construction offers significant advantages in speed and cost-efficiency, but it also presents distinct flooring challenges. At Saint Benedict’s Academy, Bostik’s technical team identified two primary concerns during their initial site assessment.
Moisture testing revealed a split condition across the building. The ground floor recorded elevated humidity levels requiring a surface-applied damp proof membrane, whilst the upper floor tested satisfactorily dry and did not require additional moisture protection.
The second challenge centred on the joints – the seams where individual modular units are bolted together. These joints, measuring between 3mm and 6mm, are subject to vibration and slight lateral movement. Without proper treatment, they could telegraph through the floor covering or compromise the integrity of the installation. A flexible, resilient solution was essential to accommodate this movement whilst maintaining a smooth, level surface.
“Modular builds move quickly, so we needed a flooring system that could keep pace with the programme whilst addressing the technical issues specific to this type of construction,” explained Emma Wilson, Contracts Director at Envira Floors Ltd. “The joints were a particular concern – we needed a solution that would remain stable over time.”
A COMPLETE SYSTEM APPROACH
Following a comprehensive site inspection and moisture assessment in accordance with British Standards, Bostik’s Technical Consultant specified a complete system solution tailored to the project’s requirements.
The first phase involved addressing the joints using Bostik GRIP X910 FILL & WOOD, a two-component resin-based primer and filler. This product’s high bond strength and inherent flexibility made it ideal for accommodating the slight movement at the joint interfaces. The material was trowelled into the joints to create a level, stable base that would flex with the substrate rather than crack or delaminate.
For the ground floor, where moisture readings exceeded acceptable levels, Bostik specified HYTEC P510 RENORAPID – a fast-drying, single-component damp proof membrane. This two-coat system provides protection against moisture levels up to 95% RH and dries in just 1–2 hours per coat, allowing the installation to proceed without lengthy delays. The rapid cure time was particularly valuable on a fast-track modular project where programme adherence was critical.
Once the DPM had fully cured, the entire substrate was primed with Bostik GRIP A526 UNIVERSAL, a water-based acrylic dispersion primer. This multipurpose product improved the bond of subsequent layers and extended the working time of the smoothing compound for an optimal finish.
The smoothing phase relied on Bostik SL C530 FLEX, a fibre-reinforced, flexible smoothing compound with a compressive strength of 30N/mm². Its flexibility made it particularly suited to substrates subject to minimal vibration or movement, whilst its rapid-setting characteristics aligned with the project’s tight schedule. Applied at a thickness of 3mm, it provided a smooth, level surface ready to receive the final floor covering.
“Bostik’s technical support throughout the installation was invaluable,” added Emma Wilson. “They didn’t just recommend products – they visited the site to support the installation team, which made a real difference to the quality and efficiency of the work.”
The final floor finish comprised sheet PVC, in the form of Altro Walkway™ 20 safety flooring, bonded using Bostik STIX A800 PREMIUM – an ultra-high-performance adhesive designed for resilient floor coverings. With its strong initial grab, extended open time, and very low VOC emissions, STIX A800 PREMIUM delivered a reliable, long-lasting bond suitable for the high-traffic demands of a school environment.
ON SCHEDULE
The flooring installation at Saint Benedict Catholic Voluntary Academy was completed on schedule, with the Bostik system solution successfully addressing both the moisture and bay joint challenges inherent in the modular construction. The combination of rapid-curing products and expert technical support ensured minimal disruption to the overall project timeline and aligned with Algeco’s overarching modular construction programme.
“The team were really happy with how the products performed,” Emma Wilson confirmed. “Everything went smoothly, and the client was delighted with the finished result. It’s exactly the kind of installation you want – fit for purpose, on time, and problem-free.”
The project demonstrates the importance of selecting the right system for the specific demands of modular construction. By combining comprehensive site assessment with targeted product solutions, Bostik ensured a durable, high-performance flooring installation that will withstand the rigours of daily school life for years to come.
For more information on the technical support and comprehensive floor preparation and adhesive systems available from Bostik, visit www.bostik-profloor.co.uk
