Industrial Epoxy Floors: Variety in Systems and Usage

Posted by Mike Mincemoyer on Oct 10, 2014 2:00:00 PM

Commercial urethane mortarsLast Thursday, Dave and I went to see three commercial prospects in northern Virginia and Maryland. That, in itself, was not unusual. What was bizarre was the variety of prospects we went to see in just one day.   I’ll review them in order to show how broadly epoxy coatings can be applied in different industries. 

Urethane Mortars for a Dairy?

About a week before our first appointment, we had received an inquiry through our website inquiring about flooring for a cheese making room at a small dairy.  The owner had obviously been doing some research, as his submission included questions about urethane mortars. 

Urethane mortars are specialized polymer coatings that are applied thick (typically around ¼”) and provide the characteristics in the figure below.  They are common in food processing plants and large dairies.  

In this case, the 1,200 square feet of the cheese making floor did not require urethane mortars and their associated costs.  The heaviest items rolling over the floors were only 500 pounds.  No high heat was present from equipment and the concrete was not subjected to thermal shock.  

We only need to remove the thin epoxy primer and urethane applied by the owner, install cove base around the perimeter and apply a Novolac epoxy system (if this sound familiar, it’s because we applied the same system to the Cumberland Creamery in Mechanicsburg and parts of the new P&G distribution facility).   This type of system will only require 3 days for installation and will be worked into their seasonal shutdown.

Coatings replacements for an Animal Hospital?

Our second stop involved the kennel area of an animal hospital.   Coatings had been applied by a coatings outfit from New Jersey, but that company was unresponsive to the staff’s calls and emails about several failures in the industrial coatings.  Originally installed with Novolac coatings (overkill – in my opinion) and then recoated twice with decorative quartz coatings (also overkill for this kennel), the coatings were now over ¼” in total thickness.  Floor was pealing up in one part of the center aisle and was obviously floating on top the concrete in another (tapping on the floor made a hollow sound not found in the bulk of the aisle).  

Two competitors had already been contacted. One did not want to come out to see the project and the other only wanted to do the job if they could remove everything and start over.   A total removal would require closing the kennel for an extended period as all polymer cove would have to be broken out of each individual dog kennel and off all of the walls.  

Our proposal involved just repairing the areas of the aisle where the coatings were disbanded and then recoating the floor with a decorative chip floor to add profile and look cleaner.  The cove base and individual kennels would not be touched. Instead of closing them for over a week, we could apply these new epoxy coatings in just two days.

Epoxy Coatings for a Crematory?

Last, we visited an active crematorium undergoing a major upgrade.   Located in a building that is at least 50 years old, the floor is heavily pitted and scarred.   Currently covered under epoxy paints installed by the staff, the floor must be upgraded to meet Maryland regulations.  

Due to the potential for hazardous fluids that could be corrosive in nature, we proposed installation of a high build, Novolac epoxy floor on approximately 3,000 square feet.  This epoxy system will be similar to what we have installed at a funeral home in Harrisburg. This Novolac system will require higher builds to end with a clean profile, since much of the floor will require shot blasting to a CSP-3 profile to remove dirt, paint and other contaminants from the pitting in the concrete. 

This project will require coating the floors in three parts, to allow the site to remain functional as we install the coatings.

Wide Range for Industrial Coatings

These three appointments are just the beginning of where industrial coatings can assist a business.    Check out Our Commercial Customers by Type of Business page to see how broadly we have applied different industrial coating systems.

 As mentioned earlier, industrial coatings are not always just layers of epoxy. They can include polyuria, urethane, MMA and polyaspartic.  Industrial coatings can be sand reinforced, slurries, mortars and trowel down.  

The amount of different industrial coating solutions is broad, but is dwarfed by the range of places they are installed for commercial and industrial use.


Commercial floor coatings make perfect business partners!

Topics: Commercial Flooring, Concrete Repair, Industrial Flooring

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