Projects
BMW Rushcutters Bay
If any project proves how critical correct floor preparation is, it’s this one—and it shows why preparation is more than a step; it’s the foundation of performance and safety.
Over 3,500 m² of coating failed after another contractor skipped proper preparation. The result was widespread delamination, flaking, and patchy adhesion that created trip hazards, exposed concrete dust, and daily safety risks for staff and equipment.
To keep the site productive, we staged the works in three phases and operated after-hours, coordinating with the client so traffic could be switched back onto cured areas each morning. Final QA included adhesion testing, gloss and thickness checks, and a detailed handover with care guidelines.
We began by isolating work zones and removing the failing system, then mechanically prepared the substrate: diamond grinding to achieve a consistent CSP 3 profile, crack chasing and filling, edge detailing, and thorough HEPA vacuuming. Moisture checks and pull-off tests confirmed the slab met the manufacturer’s specification. Only then did we apply the full MotorTuff system—primer, high-build body coats for impact and chemical resistance, and a durable topcoat with the specified slip rating—ensuring uniform film thickness across the slab.
The outcome? A safe, high-performance floor that looks sharp, resists wear, and is built to last—backed by documented preparation, compliant installation, and a warranty the client can rely on.
Royal Flying Doctor Service (RFDS)
It was an absolute privilege to coat the floors for the Royal Flying Doctor Service in Dubbo – a team that keeps Australia flying and saves lives every day. Projects like this demand precision, reliability, and zero compromise on safety, and we approached it with that standard from the first site walk.
We began by isolating work zones and mechanically preparing the slab: diamond grinding to achieve a uniform CSP profile, edge detailing around columns and door thresholds, and thorough HEPA vacuuming to remove fine dust.
Each coat was laid to the specified film thickness with meticulous cutting-in and roller finish, ensuring consistent coverage through high-wear paths, turning circles, and service bays. The final build delivers a hard-wearing surface with excellent abrasion and chemical resistance, easy day-to-day cleaning, and reliable traction where it matters most.
With the surface correctly keyed and clean, we applied three coats of EpiMax 333WB-SR, a water-based, slip-resistant epoxy chosen for its durability, low odour, and fast return-to-service – ideal for an aviation environment with continuous traffic and strict clinical standards.
To complete the project, we incorporated the RFDS logo inlaid into the floor, templated and masked to exact proportions for crisp edges and long-term integrity. Staging was coordinated with site operations so aircraft support and clinical services remained uninterrupted, and a detailed handover provided maintenance guidance to maximise lifespan.
The result is a smart, resilient floor that reflects the professionalism of the RFDS – safe underfoot, simple to maintain, and built to perform in the demanding conditions of aviation and healthcare.
Project Coordination – Mazda Car Dealership
The Mazda Car Dealership in Canberra needed to expand their growing business, with extensions and renovations throughout their current establishment. Their 2000m2 workshop had a delaminating floor and they were looking for a new system that would be able to withstand the constant motor vehicle traffic, oil and fuel spills. We recommended Hychem Motor Tuff, a system that has been used for many car dealerships.
The Dealership required to continue trading during the flooring upgrade, we worked closely with the builder and Mazda key personal to arrange a program both parties were happy with and devised the workshop, so Mazda were able to continue operating.
The final stage was 900m2 in the workshop service bays. It was critical that we were able to complete these works within 5 days, including 3 days over a long weekend.
Our first day included grinding to remove all existing coatings to bring the concrete to a clean surface.
We continued these works throughout the evening allowing us to install the trowel coat first thing the following day to streamline our process.
The following day, we treated all existing control joints and followed on with installing GPT epoxy and broadcasted with 18/40 sand.
On day three, our team swept and vacuumed the excess sand, cut all control joints back through the concrete slab and installed the first coat of SF20FG.
On day four we installed the second coat of SF20FG with the Mazda dark-grey colour to the service bays, then followed with the Mazda light-grey colour to the remaining floor.
On day 5 we installed the final coat Hychem PA500. This is a sacrificial protective layer that is a highly durable coating and allows easy maintenance.
On day six Mazda were able to move back into the workshop and continue to trade.
The key managers at Mazda and Project Coordination were very happy that the timeframe was met with no delays or hassles during the process. The floor finish was exactly how they imagined and met their needs accurately.
NSW Project Feature – Mid North Coast Correctional Center
This was the first time BAVAP had worked with Watpac, who were looking for an applicator that could achieve the correct finish within a tight timeframe.
“The manufacturer, Hychem, recommended us. We had previously used Hychem on the Junee Correctional Centre project which was completed this year so they knew we were quite comfortable with the corrections environment,” said Anja Peschler, Director.
“The Hychem product had already been specified by the design team but we would have recommended them regardless,” said Anja. “We have a very strong relationship with manufacturers.
With their technical expertise they can meet us in the middle to solve the unusual situations that emerge on any project.”
To ensure the project ran smoothly, BAVAP drew on their combined experience of 50 years including specialist experience in correctional facilities.
“Once we got started the project was straightforward. We had good communication with the other trades onsite and the builder. It’s nice to work with people you know and trust, and who know that they can trust you to get the job done,” explained Anja.
Regardless of the size or type of project, BAVAP’s first goal is to achieve outstanding finishes of the highest quality. “We hold ourselves to delivering better than acceptable finishes,” said Anja. “We pride ourselves on keeping up with our commitments which takes the stress away from our customers because they know what they will get.”
Aircraft Hangar (Bankstown)
A 3000 m2 aircraft hangar in Bankstown had a failing epoxy coating causing daily grief. We worked closely with the client from the very beginning when we first inspected the project. Test were conducted to rule out any underlying issues with the substrate as moisture, at the time seemed to be a concern. Moisture was not the issue; problem was resolved, and we moved on to providing onsite samples.
The hangar could not be closed for a long period as aircraft were booked in for servicing, so we ensured we had a program that fitted their timeframe.
Our first step was to cut out all existing joints, as the concrete was damaged along the joints. We filled the joints with epoxy and re cut, leaving new straight lines and repaired the damaged concrete.
We then started on the floor preparation by removing all existing coatings and brought the slab to a CSP4 finish to allow a strong bond. We were then ready to start coating. We trowelled down our first coat with a full broadcast to allow the new coating to look flat without any imperfections. After the first coat was down, we jumped back onto the grinders to pass over the sand allowing the floor to be smooth and aesthetically pleasing.
A further two coats of high build epoxy were installed ensuring the floor would withstand fuel jet oils, heavy traffic, etc. Our last step was to fill the joints with polyurethane and carry out linemarking where it was required.
We were able to hand the floor back just before schedule and the end result looked fantastic. The client was very pleased and they are back servicing aircraft with minimal down time.
