Case Study Food Manufacturing Flooring

Food Production Flooring System 

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Project Overview 

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.

Project Details 

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

The Process

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

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Challenges

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.

HPS's Solution

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.