A local food manufacturer located in Lancaster, Pennsylvania was experiencing flooring issues in their dock room. Because they deal with food, the room is subjected to routine cleaning with strong chemical cleaners. Epoxy coats won’t tolerate this much moisture exposure. So we had to offer a stronger flooring solution that could withstand the constant moisture, and hold up against the tough chemicals. Additionally, because the floor is exposed to so much water, it is important that the floor offers slip resistance. So, we proposed installing a urethane cement flooring system, that included a cementations aliphatic urethane top coat, and aluminum oxide broadcast.
Urethane cement offers excellent protection from excess moisture, and has the durability to be cleaned in abundance without wearing down. Aliphatic urethanes offer excellent color retention, resistance to UV rays, and are also stain and chemical resistant, increasing the level of protection from chemical insurgents that may deteriorate the concrete. And to fulfill the customer’s slip-resistance request, we performed a double broadcast of aluminum oxide into the floor. Aluminum oxide is more granular than sand, providing a greater bite into the soles of plants shoes, helping to prevent slippage.
As with any flooring project, the first step is to profile the floor. A profiled floor will have ridges and valleys that offer greater adhesion to the flooring material. In this situation, we opted to profile the floor using a planetary grinder, armed with diamond studded grinding heads. The planetary grinder removed the failed top coat, and other contaminants that may have been present in the floor. Contaminants and failed top coats reduces the level of adhesion, which creates vulnerable locations with the new material. Any vulnerable location has a greater chance of creating a floor failure.
After the floor has been adequately profiled, it will be time to apply the urethane cement floor. Urethane cement floor is a trowel application, which requires mixers, runners, and installers. The mixers will mix the urethane cement according to the instructions. After mixing, they will hand off the mix to the runner. The runner will place the mixed material onto carts, and deliver the material the installers. Using hand notched hand trowels, the installers will then spread the urethane cement over the abraded floor. Depending on the scope of the work, urethane cement is often applied at either 3/16” or ¼”. And because the customer requested a slip resistant floor, the installers will follow by broadcasting the aluminum oxide onto the surface.
After the urethane cement has cured for a day. The mix team will return to prepare the aliphatic urethane. The aliphatic urethane requires a similar mixing procedure. After mixed, the runners will deliver the material to the installers. Cementitious aliphatic urethane has less viscosity than urethane cement, and can be applied using squeegees. The installers will apply the material using squeegees. And as the designated installer spreads the material, the extra installer will broadcast additional aluminum oxide over the cementitious aliphatic urethane.
The final product will fulfill this Lancaster, PA customer’s requests, by offering a slip resistant floor with a coefficient friction of 0.08, and by creating an impervious floor that is not susceptible to excess moisture or caustic cleaning products.