UltraFloor gets into shape at David Lloyd

A number of materials across Instarmac’s market-leading product ranges have been used to repair a concrete floor at Europe’s leading health, sport and leisure group – David Lloyd.


With 126 clubs and more than 600,000 members, David Lloyd is the perfect destination to stay fit and healthy. In February 2022, the mezzanine floor at their Manchester site had become damaged and needed to be repaired.

The Challenge

This was a particularly challenging installation as the repair took place on a mezzanine floor above the swimming pool. The vibrations caused by weights dropping on the floor had resulted in the concrete underneath the gym tiles to break up causing irreparable damage.

What’s more, this area of the building is naturally very hot and humid and therefore the drying times of products are often affected.

The Solution

To begin the repair, experienced flooring contractors, HB Flooring, removed the broken concrete from beneath the existing gym floor to expose the steel subfloor. To prevent any future damage, and to ensure the new concrete keyed to the subfloor, HB Flooring applied UltraScape resi-bed– a resinous mortar than can withstand vibration.

To build up the subfloor, UltraCrete QC10 F, rapid set flowable concrete was then applied at an 85mm depth. UltraCrete has a long history of manufacturing tried, trusted and tested high specification concretes. With that in mind, it was unsurprising that HB Flooring chose to use QC10 F – a concrete that has been proven strong enough to withstand gym weights being dropped on it, without breaking up.

To prepare the area for tiling, Level IT Top was then applied to the 70sqm area. Level IT Top is a polymer rich, high strength, single part, cementitious smoothing underlayment which incorporates recycled raw materials. Formulated for exceptional abrasion resistance, Level IT Top has been designed for use a finished wear surface in both industrial and commercial applications.

What’s more, Level IT Top has a working time of 30-40 minutes, can receive foot traffic after 2-3 hours and forklift traffic after as little as 36 hours – perfect for projects with a quick turnaround such as this one.

To complete the installation, HB Flooring fitted Idass specialist gym tiles, as per the David Lloyd specification.


The project was completed in just one week in February 2022. Thanks to HB Flooring’s expertise and Instarmac market-leading materials, David Lloyd members are once again able to enjoy the gym’s world-class facilities.

For more information about UltraFloor and their range of subfloor preparation materials, please contact their team of flooring experts by calling +44 (0) 1827 254402, emailing ultrafloor@instarmac.co.uk or visiting ultra-floor.co.uk.

Products used

Level IT Top

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QC10 F: Rapid Set Flowable Concrete

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James Thatcher

We have a very close working relationship with Josh, who always go the extra mile to ensure we continue to deliver the great level of service that customers of the PTT Group have come to expect.

Supply Chain Manager, PTT Group

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