2 flooring systems; the effects of composition and application

Flooring systemsThe Effects of Composition and Application

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Flooring sysTEms The Effects of Composition and Application

PrEFACE

ProblEmThe food processing economy is growing steadily and you have determined that the addition of a new facility will best help you meet the increased demand. You have toured existing facilities and you are concerned that the flooring systems in these buildings do not provide protection from the typical forms of floor abuse within a food processing facility.

You have acquired a site that provides the required acreage for current and future demands, transportation access to major thoroughfares and appropriate space for staff parking. With the construction of a new facility, your goal is to incorporate a flooring system that will provide the characteristics needed to achieve protection from the everyday production challenges. What concrete substrate should be used? Should the floor have an epoxy or polyurethane finish? How is the floor finish applied?

soluTionIn order to design and construct the floor system within a food processing facility, you must understand a floor’s composition, characteristics, reactions to finishes and applications before choosing the correct system.



ConCrETE (subsTrATE) The intent of this investigation is to determine which industrial flooring system is best suited to meet the needs of a specific food processing facility. It is important to understand that it is the concrete substrate and its exposure to chemical, mechanical and thermal aggressions that will determine which flooring system should be used to provide the highest level of protection. Because the concrete substrate is the building component at risk, an understanding of its composition and behavior will be reviewed.

Concrete is the mixture of water, large and small aggregate, and Portland cement. Portland cement mixed with water creates a paste that coats the surfaces of the aggregates, hardens and gains strength as it dries. The strength and durability of the rock-like mass is achieved by the proportional mixing of ingredients. If the amount of paste is not great enough to fill the voids between the aggregate, the finished concrete will produce a honeycomb surface and be porous. However, if there is more paste than required, the surface will be smooth but the concrete will be likely to shrink and require frequent patching, which could be a costly error.

While the proportion of the basic ingredients is the key to providing the correct composition, there are a variety of other components within the concrete that will change and provide the characteristics needed for a specific condition. The amount of time to set, the release of heat during the cure process, the introduction of microscopic air pockets to combat a freeze/thaw effect and the introduction of fly ash into the Portland cement mix all provide different qualities that address the needs of a specific facility or application.

ConCrETE ingrEDiEnTs WATErThe use of potable water in mixing the concrete batch is not necessary; however, the use of water with excessive impurities might affect both the setting time and strength. The water should be tested to verify that levels of chloride, sulfates, alkalis and solids are within approved ranges to prevent concrete failures such as efflorescence, corrosion of reinforcement, staining, volume instability and reduced durability.

AggrEgATEsCoarse aggregate (gravel or crushed stone) and fine aggregate (sand) comprise 60 to 75 percent of the concrete’s volume. Desired thickness and end use will determine the type and size of the aggregate used.

PorTlAnD CEmEnTIn 1824 Joseph Aspdin, an English mason, named his recently patented cement product ‘Portland’ cement. The term ‘Portland’ was chosen because he felt that the color of the mixture resembled the natural limestone located on the Isle of Portland in the English Channel.

This appearance is achieved by combining calcium, silicon, aluminum and iron. Gypsum is then added in the final grinding process to regulate the setting time of the concrete. The raw materials used to create the cement are limestone, shells, chalk (or marl) shale, clay, slate (or blast furnace slag), silica sand and iron ore.

Fly AsHThe use of volcanic ash, known as pozzolanic, was introduced as a component of the ancient Roman aqueducts and building structures. Fly ash, having similar properties to the ancient pozzolanic, greatly improves the strength and durability of concrete. Also known as flue-ash, fly ash is a residue generated during the combustion of coal. The ash that does not rise is known as bottom ash and the ash that rises and is caught in an electrostatic precipitator or particle filtration equipment before reaching the chimney is named fly ash.

There are two classes of fly ash: Class F fly ash and Class C fly ash. The primary difference between the two classes is the percentage of calcium, silica, alumina and iron. Class F fly ash can have a volatile effect on the entrained air content in concrete, reducing its resistance to the freeze/thaw damage. Class F fly ash also contains less than 20 percent lime and requires the use of an activator. For these reasons, Class F is seldom used. Class C fly ash has more than 20 percent lime and does not require the addition of an activator.

As a result, Class C fly ash is the primary additive to Portland cement. While its spherical shape increases the workability of the cement and reduces the amount of water needed, it also has the ability to increase the concrete’s strength, chemical resistance and durability. Fly ash can be substituted for up to 30 percent of the standard Portland cement content of concrete.

There are five basic types of Portland cement.

• Type i – general purposeThe composition of Type I is suitable for all uses where special properties are not required. An example of a special property would be a need for temperature control during the hydration of the concrete.

• Type ii – Precaution against moderate sulfate action When concrete is located in a structure that comes in contact with groundwater drainage containing sulfate concentrations, the composition of Type II is most appropriate. The moderate speed at which the heat is released during the hydration stage is less than that of Type I. Type II is best suited for structures of considerable mass such as retaining walls.

• Type iii – Achieves high strength quickly Type III is similar to Type I but contains a slightly higher amount of gypsum and a finer grind. When compared to type I and II, this modification obtains the seven day compressive strength in just three days and its twenty-eight day compressive strength in just seven. Because of this reduction in time, the long-term strength is reduced. Type III is typically used for the construction of precast concrete products because of its quick turnover time.

• Type iA, iiA, iiiA – Air Entraining This modified version of Types I, II and III introduces an air-entraining agent that produces microscopic air bubbles which create air pockets allowing space for the concrete to expand and contract during the freeze/thaw process. These air pockets comprise 9 to 10 percent of the concrete volume.



• Type iV – minimization of heat generated Type IV should be used in massive concrete structures such as a gravity dam where the temperature rise during the curing period is a critical factor. The speed of heat loss during the hydration period is low and the strength of the composition is developed at a slower rate than Type I.

• Type V – Precaution against severe sulfate action Type V is sulfate-resistant, and should be used when the concrete is exposed to high levels of sulfate typically located in the adjacent soils and groundwater.

ConCrETE ProDuCTion ProPorTioningWater, large aggregate, small aggregate and Portland cement comprise the mix that, when designed properly, provides a workable concrete that is both durable and strong. Typically, the mix is 15 to 20 percent water, 60 to 75 percent aggregate and 10 to 15 percent cement. If an air-entrained agent is included, it will make up 9 to 10 percent of the concrete volume. (Figure 1)

The workability of the concrete is determined by the quality of the paste. The strength of the paste depends on the ratio of water to cement. This ratio is the weight of the water divided by the weight of the cement. Obtaining a high quality concrete is produced by lowering the water-cement ratio without sacrificing the workability of the concrete. Typically, using less water produces a higher quality concrete but only if it is properly placed, consolidated and cured.

HyDrATionThe setting and hardening of the concrete mixture begins with the introduction of water to the Portland cement. This process, known as hydration, is the chemical reaction that begins when a node forms on the surface of each cement particle. As the nodes expand and adhere to the adjacent aggregate, the process of progressive stiffening, hardening and strength development creates a workable mixture that will become a water-insoluble concrete.

CuringOnce the concrete has hardened enough to resist disfiguring marks and blemishes, known as marring, the process of curing will begin. Curing is the prevention of evaporation that can be achieved by applying moisture retaining fabrics such as burlap or cotton mats, sprinkling of water fog, or sealing the surface with a plastic or special curing compound to ensure that the hydration process continues. Much of the hydration and strength gain occurs within the first month of the concrete life cycle and will be governed by the specific mixture proportions, climate temperature, moisture conditions and scheduling parameters.

CHEmiCAl ADmiXTurEs WATEr-rEDuCingThe traditional water-reducing agent reduces the amount of water needed by 5 to 10 percent, which increases the concrete’s strength without increasing the amount of cement, thereby reducing the water-cement ratio. The development of a mid-range admixture reduces the water content by 8 percent and provides a more consistent setting time within a wider range of temperatures.

rETArDingWhile having the additional ability to act as a water-reducing admixture, the primary function of a retarding agent is to counteract the acceleration rate of the concrete that occurs in hot weather conditions.

ACCElErATingTypically used in cold weather conditions, this agent increases the rate of strength development and reduces the time needed for curing, which allows the finishing operations to begin earlier.

suPErPlAsTiCiZErThe addition of this agent reduces the water content by 12 to 30 percent and can be added on the job site to make a high-slump flowing concrete. The effect on the concrete is an increase in fluidity rendering it workable and able to be placed with little to no vibration or compaction. Also referred to as a plasticizer or high range water reducer (HRWR), the chemical reaction remains active for only 30 to 60 minutes, and the concrete becomes unworkable quickly.

Air-EnTrAiningThis surface-active agent stabilizes the microscopic air bubbles that are created by the shearing action of the mixture and aggregates during the concrete’s plastic stage. When mixed properly, the presence of these voids will increase the durability when exposed to moisture during the cycles of freezing and thawing and improve the resistance to surface scalling caused by chemical deicers.

Variations in the air content is often a disadvantage when using this agent and several of the common causes to be aware of are the quality and proportions of the materials; method and duration of the mixing; and the placing and finishing methods used.

Figure 1: Concrete basics (approximate percentages)

6% air

11% Portland cement

41% course aggregate (gravel or crushed stone)

20% fine aggregate (sand)

16% water



ConCrETE bEHAVior While the ingredients of the mixture can be adjusted, chemical agents can be introduced and finish protectants can be applied, the natural behavior of concrete will maintain its vulnerability to improper curing and unstable settings.

sHrinKAgEShrinkage occurs as concrete dries during the hydration process. The drying and shrinkage of concrete occurs over long periods of time with thick slabs shrinking slower than thin slabs. The top of a concrete slab generally shrinks more than the bottom causing the corner edges at joints or cracks to curl upward. This creates a visible rise in the concrete surface often seen at joint intersections.

CrACKingThe effect of shrinkage and curling creates a tensile stress within the concrete. As the concrete rises, the tensile stress (the force required to pull something apart until the moment it breaks) exceeds the strength within concrete, creating a separation or crack. (Figure 2)

PlAsTiC sETTlEmEnT CrACKsThese are cracks that occur during the plastic stage of concrete setting. During this stage, the solids within the mix settle while the water rises (bleed water) and if there is a restraint within the slab (reinforcing bars, etc.) the mixture above the restraint will not settle as far and create mirror like cracks along the restraints. (Figure 3)

ConCrETE DEFECTs During insTAllATion FrEEZE/THAW EFFECTConcrete has strong compression strength but its tensile strength is weak. As water is absorbed into the porous surface, the internal moisture can freeze and cause spalling and cracking. In order to avoid these effects, the use of an air-entrained agent will provide micro-scopic voids that allow the moisture to expand without damaging the concrete slab.

CHEmiCAl ATTACKBecause cement is alkaline and chemically reactive, it can be damaged by acids, alkalis, salt solutions and organics such as fermenting liquids, sugars, animal oils and sea water. The use of Portland cement types II and V will prohibit most chemical reactions.

CrAZingSmall cracks that weaken the surface are caused by water containing solid particles of sedimentation that have migrated to the surface of the concrete during hydration (bleed water). A small amount of this water is expected, but if spread throughout the slab with a trowel, the sediments will absorb back into the concrete, thus changing the water to cement ratio.

sCAllingImproper curing, forms of nitrates, and agents that contain calcium or sodium chloride (typically working together) cause flaking of the concrete surface that then breaks loose, causing the surface to peel. These flakes typically increase over time in high traffic areas.

Shrinkage and cracking

Concrete slab

Subgrade

Slab surface warmer and wetter than subgrade

Shrinkage and cracking

Concrete slab

Subgrade

Slab surface cooler and drier than subgrade

Figure 2: Concrete slab cracking

Settlement cracks

Large aggregate particlesReinforcing bars

Section A-A

Settlement cracks

A A

Figure 3: Plastic settlement cracking



sPAllingThis defect is similar to scalling except the surface breaks are larger than flakes, indicating severe problems within the concrete slab, typically caused by freeze/thaw conditions.

blisTErsAs water and air work their way up during the curing process, it causes a rise in the concrete forming blisters. These blisters, ranging from 1/4" to 4" in diameter, are not easily seen but can become chipped by direct traffic.

DusTingA loose powder layer, similar to chalk in appearance, is produced by a weak concrete surface. An unvented heat source, improper small aggregate (sand) to cement ratio or the use of bleed water are possible causes of this deterioration.

ForEign obJECTsDebris from the surrounding job site can often work its way into the concrete while the concrete is being set and might not be noticed until the forms are removed. If fully embedded, the object will not have an effect on the coating process. However, if a foreign object such as plastic stripping or rope is exposed, it must be removed, typically by chipping; then the concrete must be restored.

EFFlorEsCEnCEAs water migrates from a drying concrete, water-soluble salts within the concrete work their way out to the surface in the form of white chalk.

sPECiAl Floor sysTEms When investigating the flooring system best suited for a food processing facility, the driving factors that need to be addressed are the chemical exposure, abrasion, impact and thermal shock. While each facility will face similar challenges when looking at resistance to moisture vapor, surface gloss, slip resistance, odor, repair-ability, project schedule, etc., there will not be one ‘perfect’ system to be used in all facilities.

High Performance Floor Surfacing Systems (HPFSS) are used to protect concrete substrates from chemical, mechanical and thermal aggression. The two systems most often used are the Chemical Resistant Brick and Tile (CRBT) system, composed of grout, setting bed, ceramic tile, paver tile and/or dairy brick and the monolithic system, formed by resin and/or aggregate types.

CHEmiCAl rEsisTAnT briCK AnD TilE sysTEmsIn the past, bulky, conventional, thick bed methods were employed for the installation of industrial ceramic tile, paver tile and dairy brick applications. With the improvement in adhesive technology, a more efficient and environmentally sensitive use of materials has been introduced, resulting in a reduced weight, lower cost of material and a more efficient use of natural resources. However, the use of the CRBT in industrial installations places a large stress on the tile and paver application and, in turn, an environment that is challenging not only for the finish tile or paver but also for the installation system materials.

Because the surface of this system is not monolithic, the use of cement grouts located between the tile and brick are susceptible to absorption. Even if sealed with a high level of epoxy sealer on a regular basis, the mortar will easily stain and become inundated with debris. The severity of these constraints when using the CRBT system is reflected by the use of the monolithic system more frequently and, because of this tendency, the following investigation will focus on the monolithic resins only.

monoliTHiC sysTEmA monolithic system is an aggregate-filled, resin based, coating system that provides a seamless surface able to withstand chemical exposure, abrasion, impact and thermal shock. Epoxy, Acrylic, Polyurethane, Polyester and Vinyl esters are the primary forms of resin.

Each resin is unique in its ability to protect the floor from the typical abuse found within a food processing facility. The following investigation reviews the characteristics of each resin along with several methods of application.

Epoxy ResinEpoxy is the combination of two chemicals, referred to as (A) the resin or compound and (B) the hardener or activator. Part (A) usually consists of Bisphenol A or Bisphenol F. Bisphenol A is a general purpose, cost-effective resin that has an excellent alkali resistance, good acid resistance and fair-to-good solvent resistance. Bisphenol F is a low viscosity material that provides excellent alkali resistance, and a better acid and solvent resistance than Bisphenol A.

Part (B), the hardener, is an industrial epoxy coating catalyst that falls into one of five standard categories: Aliphatic and cycloaliphatic amines and polyamines; amides and polyamides; cycloaliphatic; amine adduct; and novolac. The chemical makeup of each of these categories, play a major role in the properties of the final cured epoxy.

• Aliphatic and Cycloaliphatic Amines and PolyaminesThis chemical solution is ammonia with one or more hydrogen atoms replaced by organic groups. The amine-based curing agents are considered more durable and chemically resistant, but most likely to produce a waxy surface layer on actively curing epoxy known as blush.

• Amides and PolyamidesThis chemical solution is ammonia with a hydrogen atom replaced by a carbon/oxygen and organic group. Unlike the amines, the amide is more tolerant to surface contact and less troubled by water.

• CycloaliphaticThis agent provides better water/moisture resistance, better weatherability, low blush and water spotting, and better chemical resistance. The composition of this agent provides more of a “structural stretch” and, in return, provides a better impact resistance.

Most top grade, high performance epoxies incorporate a blend of the cycloaliphatics into the ‘part B’ curing agent and is often used to judge the quality and performance of the final epoxy.



• Amine AdductsAmine Adduct epoxies are two-part epoxies but the curing agent actually contains a small amount of epoxy resin. Because of this unique combination, the mixture starts to cure even before type (A) and (B) are mixed. This mixture performs much like the other agents but with higher overall properties, such as a better color stability, curing at a cooler temperature and curing faster than the standard epoxy.

• Novolac EpoxyA fifth and more specialized epoxy is the Novolac Epoxy. This epoxy has excellent heavy duty chemical resistance, low odor and low shrinkage. However, it is not thermal shock resistant, will not have full chemical resistance for up to 7 days and has a tendency to chalk and discolor when exposed to UV light.

ACryliCs Also referred to as Methyl Methacrylate (MMA) this water-based floor system will cure much faster than other applied coating systems. The coating can be applied in very cold temperatures (-20° F), resist a wide range of acids and alkalis, and provide high impact and abrasion resistance. Minimum surface preparation is required and fresh applications melt and bond, creating a monolithic system that won’t peel. Reseal costs and down time are much shorter than other coatings. This system provides a much more durable finish.

The negatives are the need for adequate ventilation during application due to strong odors, low adhesive strength, and extreme susceptibility to poor adhesion in substrates that contain some level of humidity.

PolyurETHAnEs The polyurethane floor coating is a solvent based, two-component system. This coating is abrasion resistant, antibacterial, UV resistant, antifungal, and easily cleaned. In addition, this coating provides a tough and flexible surface that has excellent adhesion to concrete, tiles, metals and packing unit floors.

• Cementitious This form of urethane is thermal shock resistant, has good stain resistance, has excellent organic acid resistance and demonstrates good moisture tolerance during the curing process.

• Aliphatic This coating provides a high level of chemical resistance, good weathering properties and excellent UV protection while providing a durable adhesive quality.

• AromaticAromatic coatings are useful where UV radiation is not an issue. Polyurethane coatings made from aromatic polyisocyanates are very sensitive to oxidation and, as a result, prone to degradation in direct exposure to sunlight.

• AsparticThis coating is a two-component, low VOC, urethane resin designed for high performance protection with outstanding exterior gloss and color retention. This resin has a high resistance to corrosion, weathering, and chemicals; offers color and gloss retention; and is suitable for use in USDA-inspected facilities

PolyEsTErs/Vinyl EsTErs Polyester prepolymers are produced by a condensation reaction of organic acids and polyols. The choice of reactants will establish the resulting polymer mechanical properties, thermal stability and chemical resistance. This resin has a high solvent and chemical resistance, and the ability to withstand highly corrosive exposures. It provides a good adhesive quality, and flake fillers can be added to increase resistance to permeation by water vapor.

The negative of this resin is the creation of a trapped tensile strain (pre-stress) by the heat and shrinkage produced during its drying process. This strain can lead to cracking or disbondment, especially in very low operating temperatures, and can become brittle if not reinforced.

See (Table 1) for a synopsis of the characteristics of each resin.

Table 1: Characteristics of polymer products

Cure Bond Strength Properties Resistance Safety

Epoxies - Temperature sensitive- Mix ratios important

- Excellent - High strength- High-low uniformity

- Good wear- Moderate chemical

- Allergy- Odor

Epoxy Novolacs - Cold, wet cure - Excellent - High strength- High uniformity

- Heat resistant- Chemical resistant

- Allergy

Polyesters/Vinyl Esters

- Moisture sensitive- Catalyzed cure- Shrinkage

- Will not bond to damp surfaces

- High strength- High (low) uniformity

- Heat resistant- Chemical resistant

- Flammable- Odor

Urethanes - Humidity sensitive - Intercoat adhesion difficult

- Gloss retention- Elastomeric

- Excellent wear- Stain resistant- Weather resistant

- Allergy- Free isocyanate- VOC

Methyl-Methacrylate (MMA)

- Cures quickly- Cold cure- Shrinkage

- Moisture sensitive - Clear- Easy handling- High strength

- Abrasion resistant - Flammable- Odor



sPECiAl Floor sysTEm APPliCATion

CoATingThe positive qualities of the coating system are that it is the most economical at 40 mils or less, and provides moderate chemical resistance, easy cleanability, simple repair and maintenance, and UV protection. It also seals concrete from absorption of microorganism or contaminants, and protects concrete from sterilants.

The negatives are that it can easily scratch and develop traffic patterns, is subject to damage from impact and thermal shock, and does not mask surface imperfections. In addition, this application cannot be used to modify the slope of a substrate and will need to follow the existing contour of the substrate. (Figure 4)

sElF lEVEling sysTEms• SlurrySlurry is a thin mixture of a liquid (typically water) and a cement, plaster of Paris or clay particles. A primer is placed directly on the substrate (typically 60 mils) and is then covered with a thin topcoat.

As an intermediate priced system, the positive qualities of the slurry system are the improvement of substrate properties for thermal shock and impact, and the masking of minor imperfections. The system also requires less skill to install, thereby increasing the installed square footage per day.

The negatives are that it is not suitable for sloped surfaces, requires more skill to install than coatings alone, and is less resistant to thermal shock and impact than mortars. (Figure 5)

• Broadcast systemsForming a seamless, monolithic floor, the broadcast system is composed of low viscosity, 100 percent solid epoxy resin and aggregate filler in the form of finely graded silica within the slurry mix. The combination of slurry and broadcast aggregate will range from 60 mil to 1/4" depending on the amount of mechanical abuse, impact and abrasion.

The broadcast system provides a good slip and chemical resistance, and is most suitable for areas of light to moderate chemical, impact and traffic exposure. Similar to the slurry system, the addition of the broadcast system is not suitable for sloped surfaces and is less resistant to thermal shock and impact than mortars. (Figure 6)

• Thick-Mil TroweledThis system is a 3/16 - 3/8" thick mortar material with aggregate fillers in a resin matrix placed on a primer covering and substrate surface. The troweled flooring system provides the highest physical properties and is resistant to impact, thermal shock and abrasion. This application is suitable for sloped surfaces, masks surface imperfections and is able to provide pitch toward the drain while having the lowest life cycle costs.

Topcoat at 8-10 mils

Slurry at 60 mils

Primer at 6-8 mils

Concrete substrate

Figure 5: Slurry-Smooth

Topcoat at 6-20 milsOptional intermediate coat at 8-16 mils

Primer at 6-8 mils

Concrete substrate

Figure 4: Coatings

Topcoat at 10-20 mils

Broadcast and grout coat

Slurry at 60 milsPrimer at 6-8 mils

Concrete substrate

Figure 6: Slurry-broadcast slip resistant



The negatives of this system are that the thickness of the application might affect equipment and door clearances; it requires the highest level of skill and additional time for installation; and it has the highest initial cost. (Figure 7)

sAFE QuAliTy FooD (sQF) CoDE After reviewing the special floor systems and applications, the development of a sanitation and health program for all facility flooring systems must be addressed. The SQF is one of several food management programs that is recognized worldwide and benchmarked by the Global Food Safety Initiative (GFSI). This program develops specific management training to develop, document and record safety procedures while working directly with HACCP plans. This program has a three level certification that can be obtained through the implementation of the safety process and procedures.

While this safety code is composed of 16 modules that include a checklist for all sections of the food industry, the checklist for a food processing facility is located in module 11. Below is a clip from the SQF Code, 7th Edition, July 2012.

sQF-CoDE-ED-7-moDuAl – CoVErs All FooD ProCEssing TyPEs

11: FooD sAFETy FunDAmEnTAls – gooD mAnuFACTuring PrACTiCEs For ProCEssing oF FooD ProDuCTs (gFsi, Ei, Eii, Eiii, EiV AnD l)

11.2 ConsTruCTion AnD ConTrol oF ProDuCT HAnDling AnD sTorAgE ArEAs

11.2.1 mATEriAls AnD surFACEs• 11.2.1.1 Product contact surfaces and those surfaces not in direct

contact with food in food handling areas, raw material storage, packaging material storage, and cold storage areas shall be constructed of materials that will not contribute a food safety risk.

11.2.2 Floors, DrAins AnD WAsTE TrAPs• 11.2.2.1 Floors shall be constructed of smooth, dense impact

resistant material that can be effectively graded, drained, impervious to liquid and easily cleaned.

• 11.2.2.2 Floors shall be sloped to floor drains at gradients suitable to allow the effective removal of all overflow or waste water under normal working conditions.

• 11.2.2.3 Drains shall be constructed and located so they can be easily cleaned and not present a hazard.

• 11.2.2.4 Waste trap system shall be located away from any food handling area or entrance to the premises.

(SQF Code, 7th Edition, July 2012)

sElECTing A Floor sysTEm Chemical exposure, abrasion, impact and thermal shock are the four macro-categories of adversities that every food processing flooring system will encounter. Is there a perfect floor coating and application that will protect a food processing facility? Yes, however the final decision must be based on the challenges that are present in that specific facility. What are the environmental conditions for this project? When must this facility be up and running? Is cost a factor? What form of cleaning, pressure and/or chemical mixtures will be required? Is there high traffic or low? The needs will be specific to each facility as will the solutions.

ConClusionThe mixture of water, large aggregate, small aggregate and Portland cement; the manipulation of strength, speed and workability; and the resistance to chemical contact, abrasions, high impact and thermal shock are the components, that when designed for a specific facility, provide the perfect flooring system.

Looking for the best flooring system for your facility will bring forth many solutions and each will address the challenges at hand. However, with an understanding of the systems’ composition and how it might react to your specific conditions will increase the value of the investigation and in turn clarify your solution.

Kevin Franz, AIA, LEED AP BD+CProject ArchitectA M King Construction, LLC

References:SQF Code A HACCP-Based Supplier Assurance, Code for the Food Industry, 7th Edition, 2012 - Module 11: Food Safety Fundamentals – good manufacturing practices for processing of food products (GFSI, EI, EII, EIII, EIV and L)

Topcoat at 10-20 milsGrout coat

Trowelled basePrimer at 6-8 mils

Concrete substrate

Figure 7: Thick-mil trowelled

2 flooring systems; the effects of composition and application

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