Samsung Electronics LLC's Samsung Electronics Rus Kaluga factory complex in the Kaluga region produces more than 100 models of TVs and monitors, including QLED and Curved, with annual updates to the lineup. The company also assembles Russian servers for domestic data centers. The plant's products are sold in Russia, CIS countries, Central Asia and Transcaucasia
Samsung Electronics approached us with the task of replacing a worn coating. Initially, the floor had a topping, which broke down over time, and gaps appeared between the tiles. Later, quartz vinyl anti-static tiles were laid on top of it, but even this did not withstand the operating conditions - the tiles began to peel off, and robot trucks on small wheels lost their orientation and got stuck
The customer decided to dismantle this coating and requested a solution that would provide a smooth, durable and easy to maintain surface for a decade, without the need for constant repairs. At the same time, the coating had to meet the strict requirements of the electronics factory - no dust, anti-static and no interference with the factory's robots
Provide a solution that will withstand intensive use for a decade without the need for repair
Ensure perfect levelness for smooth movement of robot trucks and stable operation of plant equipment
Remove outdated flooring (quartz vinyl tile) and repair problems caused by its wear and tear and peeling off
Perform all work without stopping production and with no dusting
Complete repairs on assigned areas, strictly adhering to the customer's schedule
Guarantee high quality of work and ensure professional organization of the process at all stages of interaction with the Customer
The following technologies are agreed upon for this project:
1. careful dismantling and preparation of the substrate
Careful removal of quartz vinyl tiles and preparation of the substrate for the subsequent application of a new coating, eliminating strong vibrations of the floor substrate, which can damage the operation of the plant and spoil the customer's equipment
2. polished concrete technology:
Creation of a strong, wear-resistant and breathable coating with a high degree of evenness and durability
3. Dust collection systems:
Use of specialized Italian COYNCO equipment to minimize dusting in the process of work at the existing production facility
4. Floor leveling:
Use of professional Chinese XINGUI grinders to eliminate gaps between slabs and ensure geometric flatness of the pavement in a short period of time of the customer
5. Integrated approach:
Integration of solutions for technology-intensive production facilities that take into account the intensive use of robotic carts and high operating loads
1. Removal of the old coating:
Removal of conductive PVC tiles and preparation of the substrate
2. Rough mechanical grinding:
Grinding the concrete to the level required to remove defects and level the surface
3. Concrete Base Repair:
Expansion of caverns and cracks, their dedusting and filling with repair compound with subsequent technological treatment
4. Strengthening and dedusting of the concrete base:
Technological treatment of concrete to increase the strength and durability of the pavement
5. Final leveling:
Final repair of minor damages, cavities and cracks, quality control
6. Create transitions between areas with tile and new floors:
Providing a smooth transition between tile and Polished Concrete flooring for uniformity of coverage and to support the plant's robotic carts
7. Final sanding and polishing:
Chemical and mechanical polishing without dust and strong odor to achieve an aesthetic appearance and to give resistance to water and dirt
8. Cleaning and disposal of waste:
Collection, bagging and disposal of construction waste
All phases of work were completed qualitatively within the given short deadlines. Non-standard tasks of the project and the customer were solved.
The customer was satisfied with the floors and no warranty comments were received from the customer for 2025.
Samsung Electronics LLC also invited tConcrete to work on Polished Concrete flooring at their manufacturing facility in Egypt
