Case Study Food Manufacturing Flooring
Food Production Flooring System
This was a new facility for an international airline catering company. The pour was new and concern that the dehydration process was not fully achieved our design team specified a urethane cement floor system.
Beyond the moisture tolerant system urethane cements are ideal for food catering facilities to allow for thermal cycling or the exchange of varying temperatures. Seamless flooring is the preferred flooring system for all food and beverage industries. These floor systems eliminate grout lines from the previously preferred tile, also are the lowest maintenance option.
Location: Sterling, VA
Products: Dur-A-Flex; Polycrete SLB; Dur-A-Flex; Polycrete TF; Dur-A-Flex; Polycrete WR
Type of Business: Food Catering
Size/ Square Footage: 10,000 sq ft
Step 1: Preparing the slab: Diamond grinding of the slab with bush-hammer attachments to establish a deep tooth for our slurry system
Step 2: Mark out all joints to locate expansion joints for treatment after our seamless floor is installed
Step 3: Install key channels at all terminations: to allow for recommended system thickness of our applied floor while leaving similar surrounding heights of trench drains and doorways
Step 4: Install urethane cement slurry to create thermal and impact resistant floor system
Step 5: Install radial coving to all bumper walls 12-18” height and floor joints: ensuring sanitary conditions for a food-safe FDA compliant facility and low maintenance for wash down
Step 6: Apply system topcoat: Urethane cement coating; chemical resistant topcoat with thermal cycling capability
Step 7: Sawcut joints and install polyurea joint material to allow expansion contraction of our seamless system
The customer had pre-formed curbing installed for their wall systems and needed to have it food safe and FDA compliant. Due to the curbing having multiple bug-holes the entire face needed to be parged to eliminate any chance of standing water or area for bacteria to harbor.
Using a urethane cement cove mortar our installation team filled all holes in the curbing prior to installing the radial cove. After eliminating areas for bacteria and water to sit the walls were flattened with hand grinders and then our system cove base was installed.