Underwater Film Production Tank Remediation

Introduction

A major movie production company faced severe water leakage and subfloor breakdown in a large enamel-bolted filming tank. The initial concrete subfloor was actively deteriorating, causing water loss, pH instability and debris contamination that threatened sensitive camera equipment. UCL was engaged to diagnose the structural issues and deliver a seamless, heavy-duty lining solution.

Our Solution

Initial inspection revealed a powdery, weak concrete surface caused by the original floor being laid in rain and incorrectly dressed with dry cement. UCL adapted immediately, removing 10mm of the compromised layer using a concrete planer to reach the sound substrate. To resolve floor unevenness, a specialised primer and a liquid-pumped screed were applied to reinstate a true level. Once cured, this screed was diamond ground to establish an optimal mechanical profile. The enamel tank edges were sealed with mastic, an epoxy primer was applied, and the walls were hand-sprayed with polyurea to a 2mm thickness. A spray robot applied 2mm of polyurea to the floor before complete spark testing ensured a defect-free seal.

Key Benefits

• Substrate remediation — liquid-pumped screed and diamond grinding successfully corrected rain-damaged concrete to create a reliable, level foundation
• Complete water containment — the seamless polyurea lining and mastic joint treatment completely eliminated leakage around the tank base
• Water clarity protection — encapsulating the floor prevented loose aggregate from floating into the water, protecting filming equipment and maintaining pH stability
• High impact and abrasion resistance — the 2mm spray-applied polyurea barrier withstands heavy underwater rigging, cameras and production gear without failing
• Proven reliability — monolithic coverage and rigorous holiday testing delivered over a year of faultless operation under intensive filming conditions

Conclusion

By combining technical surface diagnosis, screed remediation and automated polyurea application, UCL resolved both structural subfloor failures and water loss. Delivered within tight film production schedules, the installation provided a durable, defect-free filming environment that performed without fault for over a year.