1 / 67

URETHANE CEMENTS or EPOXY COATINGS FLOORING IN A BREWERY

Presented by Norm Klapper PEC – Boulder, Colorado. URETHANE CEMENTS or EPOXY COATINGS FLOORING IN A BREWERY. Presentation Outline. Why coat concrete floors? When is the best time to coat? Contractor selection Concrete preparation Essential installation details, thickness

blue
Download Presentation

URETHANE CEMENTS or EPOXY COATINGS FLOORING IN A BREWERY

An Image/Link below is provided (as is) to download presentation Download Policy: Content on the Website is provided to you AS IS for your information and personal use and may not be sold / licensed / shared on other websites without getting consent from its author. Content is provided to you AS IS for your information and personal use only. Download presentation by click this link. While downloading, if for some reason you are not able to download a presentation, the publisher may have deleted the file from their server. During download, if you can't get a presentation, the file might be deleted by the publisher.

E N D

Presentation Transcript


  1. Presented by Norm Klapper PEC – Boulder, Colorado URETHANE CEMENTS or EPOXY COATINGS FLOORING IN A BREWERY

  2. Presentation Outline • Why coat concrete floors? • When is the best time to coat? • Contractor selection • Concrete preparation • Essential installation details, thickness • Urethane cement or epoxy topping? • Typical installation applications • Key physical properties of each formulation • Life cycle comparison and recommendations • Summary and conclusions

  3. Issues Unique to Breweries • Wet, humid conditions • Presence of caustic and chlorine-based CIP and wash down agents • Thermal shock: cold floors (<50°F) washed with hot, 180 °F water • Presence of yeast which if trapped in crevices, cracks or under coatings can easily cause delamination • Tough food grade standards apply, regulated industry • Heavy wheeled traffic, impacts from equipment, kegs, fork lifts, pallet jacks • Operations usually 24/7, little downtime allowance • Public viewing or access to brewing areas and need for aesthetics in a production area • Health and safety for personnel, slippery conditions

  4. Why Coat Concrete Floors? • Protection from Chemical Attack • CIP daily wash down, caustics, chlorine • Brewery waste products • Yeast, carbonic acid • Protection from Mechanical Wear • Impact • Wear from Pallets, etc. • Prevent cracking, abrasion

  5. Why Coat Concrete Floors…..cont. • Provide Slip Resistance for Safety • Minimize wet, slippery conditions • Aesthetics • Provide an appealing and professional look • Cleanability & Maximize Service Life • Monolithic substrate and smooth transitions to drains

  6. Second Street Brewing – Sante Fe

  7. Epoxy with Decorative Quartz

  8. When to Coat? • New Floors Best • Open area • New Construction – BEST forContractor • No contamination • Floor, drains, etc. not compromised • No equipment legs • Old Floors • With existing coating? • REMOVE ALL – clean warranty • Without existing coating? • Use correct preparation techniques

  9. Contractor Selection • Contractor MUST be certified by the manufacturer of the coating – suggest you verify • Contractor must have a proven track record of successful projects, delivered on time. • Contractor must offer a JOINT WARRANTY with the manufacturer which protects the Owner/End-User • Get References and check them!

  10. Concrete Preparation • All coatings require competent and thorough surface preparation • Mechanical • Diamond Grinding • Scarifying • Shot Blasting • Crack Chasing • Detailing – Keyways, Drains, etc. • Profile MUST be equal to an SP5 – SP6

  11. Concrete Preparation

  12. SP5 and SP6 PROFILES

  13. Concrete Preparation….cont. • All coatings require competent and thorough surface preparation • Chemicals are supplementsto mechanical techniques • Acid Etching • Chlorine or Caustic Sanitizing • Extensive hot water washing • Additional Techniques (Optional) • Flaming (Weed Burners) • High pressure air / vacuum for standing water removal

  14. Timing of Installation • Concrete age & moisture content • 28 Day Rule • Vapor barriers under new slabs - VERY important • Moisture in Concrete • Run Calcium Chloride Test • Plastic Sheet Test – ASTM D4263 • Relative Humidity Meters (RH Meters) • High early concrete • Steel trowel finish • Cure and seal? – NOT recommended • removed entirely by mechanical prep techniques

  15. HAND TROWELED – EITHER EPOXY or URETHANE CEMENT

  16. Installation Details – Perimeter Key

  17. Installation Details – Control Joint

  18. Installation Details – Crack Repair

  19. Installation Details – Expansion Joint

  20. Installation Detail – Corner Expan. Joint

  21. Installation Details – Metal Base Plate

  22. Installation Details – Drain

  23. Installation Details – Cove/Exp Joint

  24. Installation Details – Spoon Cove Base

  25. Installation Details – Cant Cove Base

  26. Installation Details – Pipe Protrusion

  27. Installation Details – Bolt Holes

  28. Installation Thickness • All formulations available in…… • Thin film (3-15 mils) • Double broadcast slurries (1/8” - 125 mils) • ¼” troweled – BEST OPTION! • Slope to drain – as thick as needed up to 1” or more, (1/8” in 10’) – CHECK FLOOR FIRST! • Self-Leveling formulations – tougher on sloped floors • Berms – created using same materials or filler patch formulations – saves $ but takes longer • Cove or no cove? Spoon or “cant” type?

  29. Urethane Cements / Epoxy Coatings • ALL providers of URETHANE CEMENTS have similar formulations • ALL have similar: • Working Time • Temperature Resistance • Chemical Resistance • Bond Strengths to substrates

  30. Urethane Cements / Epoxy Coatings • In Contrast, EPOXY COATINGS all have great variations in formulations • WIDE VARIATION in all characteristics • Working Time • Temperature Resistance • Chemical Resistance • Bond Strengths to substrates

  31. WHY THE CONTROVERSY? • Great variations in epoxy formulations and therefore varied application success • Many offered non-resin rich, top-coated (grout-coated) dry systems with high compressive strengths (>10-15,000 psi, 2-3x’s concrete!) • Harder, more brittle materials with less thermal shock resistance, reduced life spans (1-2 years!) • Urethane cements “took up the slack” and offered viable alternatives • Similar coeff. of thermal expansion to that of concrete, less likely to delaminate under thermal shock

  32. WHY THE CONTROVERSY….cont • Early epoxy failures led to: • Rise in Polyesters, Vinylesters, Methylmethacrylates (MMA) – all with high odor • Followed by lower VOC, more resin-rich epoxies, more impervious to liquids and subsequent failures. • Newer, high performance epoxy formulas which maintained resin-rich, LOWER compressive strengths and greater chemical resistance, thermal shock resistance • Flexibilized epoxies have been around decades longer than Urethane Cements and these have had wide success

  33. Flexibilized ¼” Epoxy

  34. COMPARISON of URETHANE & EPOXY TOPPINGS 1 (Assumes 1/4" Thickness, Flexible, Resin Rich Epoxies, Average Values)

  35. COMPARISON of URETHANE & EPOXY TOPPINGS 2 (Assumes 1/4" Thickness, Flexible, Resin Rich Epoxies, Average Values)

  36. COMPARISON of URETHANE & EPOXY TOPPINGS 3 (Assumes 1/4" Thickness, Flexible, Resin Rich Epoxies, Average Values)

  37. COMPARISON of URETHANE & EPOXY TOPPINGS 3 (Assumes 1/4" Thickness, Flexible, Resin Rich Epoxies, Average Values)

  38. Similar Installation Techniques • Mixing – virtually the same • Troweled – hand or power-troweled • Screed method – using screed boxes or bars • Slurry system in one or two lifts • Uses more resin compared to troweled • Finished “as-troweled” • Final coat back-rolled, seeded, top coated or not top coated • Neither system requires top coating • Top coating mostly for aesthetics

  39. Anheuser-Busch

  40. Urethane Cement – Screed Box

  41. Installation Characteristics • OPEN (WORKING) TIMES • Urethane Cement – open time, 15 minutes • Epoxy Topping – open time, 45-60 minutes • CURE TIMES • Urethane Cement – cure time, 8 hours (Fixed, not changeable) • Epoxy Topping – temperature dependent– cold cure (6 hours), fast cure (8 hours), regular cure (14-18 hours)

  42. Final Textures & Colors • Optional Textures – determined by type and size of sand media • Silica Quartz • Aluminum Oxide • Grit / Mesh Sizes – from 16 to 30 • Trade off between slip resistance and cleanability – VERY subjective • Strongly suggest sample texture offered for evaluation and approval purposes • Maintenance and safety concerns need to be balanced

  43. Recommendations? • URETHANE CEMENTS • Higher temperatures >220 degrees F • Chemicals at higher temperatures • New construction for open areas due to less open time for working/application

  44. Recommendations? • EPOXY TOPPINGS • Reasonable temperatures – 180 degrees max • Cost concerns – easier to apply, smaller crews, with usually somewhat lower installed cost • Single step – finishes with higher gloss, no top coat

  45. SUMMARY • Both urethane cements and epoxy coatings provide excellent concrete protection and safe working surfaces • Urethane Cements are formulated virtually the same – • Epoxy Coatings vary greatly • Epoxy Coatings (resin rich) have greater open times and are easier to apply – also do NOT require a top coat to finish with high gloss • Can be applied in one-step, less time

  46. SUMMARY…..cont. • Urethane cements usually require a primer coat while resin rich epoxy coatings do not and therefore can be applied in ONE-STEP • Epoxy Toppings have a lower operating temperature when compared to Urethane Cements • Epoxy Toppings have greater bond strength to a wider range of substrates

  47. SUMMARY Epoxies vs. Urethane Cements • Both are “flexibilized”, resin rich ¼” and will do the job • Urethane cements when temps > 212°F or if hot acids hit floor (>140°F-160°F) • Epoxies have better damp adhesion • Epoxies have better adhesion over quarry tile • “As-Troweled” epoxy better gloss than urethane cement troweled system • If aesthetics are vital & downtime not critical – best method for both is slurry/topcoat

  48. Conclusions • Choose the right product for the project • Base your decisions on working conditions, service conditions, temperature, aesthetics • Choose suppliers with a proven track record only – in similar brewing applications • Choose ONLY reputable contractors, not necessarily based on lowest price • Base your decision on technical documentation and not marketing hype • Get a solid, clear and unambiguous warranty statement

  49. Highly Decorative Flooring Epoxy Quartz with Top Coat

  50. Highly Decorative – Epoxy Quartz with Top Coat

More Related