Overview

Poly Up was selected for a prestigious project at Manchester University: installing a high-performance resin surface for the university’s cutting-edge Robotics Lab. This project required a seamless combination of advanced materials and expert craftsmanship across multiple teams and disciplines to create a durable, aesthetically pleasing, and functional surface. The surface would ensure students weren’t affected by mud, puddles, or dirt outside the building, enhancing the experience whilst providing environmental advantages to alternative resurfacing options.

The Robotics Lab project demanded:

• Visual Appeal: A stunning surface to complement the modern design of the lab.
• Durability: A surface capable of withstanding heavy foot traffic from students and faculty.
• Water Permeability: Effective drainage eliminates puddling and maintains cleanliness in an outdoor courtyard.

Poly Up was selected to install a 315-square-meter resin-bound surface for Manchester University’s Robotics Lab courtyard. The project aimed to create a durable, water-permeable, visually appealing outdoor area that matched the lab’s modern aesthetic while ensuring long-term functionality. This large-scale commercial project required meticulous planning and collaboration with the main contractor and Addagrip, the material supplier.

Our approach and project challenges

The project presented several challenges, including managing over 25 tons of materials on a busy construction site and adhering to a tight schedule amidst contractor delays. Precision was critical, as the installation involved a geotextile membrane and a Terabase grid system to provide a stable, porous base.

• Logistics: The project involved handling 25 tons of materials delivered on-site, which had to be stored and managed without disrupting ongoing construction activities.
• Precision Installation: The architects specified a floating geotextile membrane system with a Terabase grid. This required meticulous preparation and alignment to ensure structural integrity and aesthetic consistency.
• Tight Deadlines: Despite multiple schedule changes from the main contractor, the project must be completed within a compressed timeframe.

Poly Up’s team carefully prepared the site, stabilising the substrate before laying the Terabase grid system. A custom resin-bound gravel blend was applied in a 30mm layer, ensuring water permeability while achieving the desired appearance. Despite weather dependencies and logistical complexities, the active installation was completed in two days.

1. Pre-Project Coordination:
   • Poly Up collaborated with the main contractor and the material supplier (Addagrip) to ensure all specifications were met.
   • Risk assessments, method statements, and health and safety policies were prepared to comply with university and contractor requirements.

2. Material Handling:

1. • Delivered materials were stored systematically to avoid interfering with other site activities.
   • On-site logistics were meticulously planned, including appropriate machinery for material movement.

3. Installation Process:

1. • Substrate Preparation: Installed a geotextile membrane and Terabase grid system, allowing flexibility and thermal expansion.
   • Resin Surface Application: A 30mm layer of resin-bound gravel, using a custom blend specified by the architects, was applied to the surface. The system ensures water permeability, directing rainwater into specially installed drains beneath the surface.

4. Final Checks:

1. • Conducted thorough inspections to ensure the surface met aesthetic and functional requirements.
   • Cleaned the site to maintain Poly Up’s high standards of cleanliness and professionalism.

Results, Success and Future Planning

The result was a robust, slip-resistant, eco-friendly surface seamlessly integrated with the Robotics Lab’s cutting-edge design. Manchester University praised the quality of the work and the quick turnaround, noting the surface’s aesthetic and functional benefits. Poly Up also provided a 15-year warranty and guidance on ongoing maintenance to ensure the surface’s longevity.

• Rapid Completion: Poly Up completed the project in just two days of active installation despite schedule adjustments, minimising delays.
• Sustainability: The permeable surface promotes natural water drainage, reducing environmental impact.
• Client Satisfaction: Delivered a visually stunning and highly functional surface that exceeded client expectations.

Poly Up provides a 10-year warranty on the installed surface and 25 years on the materials, subject to proper maintenance. As part of our aftercare services, we offer an annual cleaning service to preserve the surface’s integrity and ensure warranty compliance.

Get in Touch

Are you interested in creating a stunning and durable resin surface for your project? Contact Poly Up we would be delighted to discuss your requirements!