Food Floor System
Here is a food flooring system designed for one of the largest microbreweries in NYC. Using a commercial kitchen flooring system designed to handle hot and cold water wash downs, as well as, an excellent resinous floor system for chemical resistance.
Existing Conditions: Our client was turning an old warehouse into a brand new state-of-the-art craft brewery and unfortunately they had another contractor come in and install a black coating system that was failing across the entire floor. The key to a successful food floor system is installing something that will be temperature change tolerant, slip/chemical resistant, cleanable, and sanitary.
Preparation of existing condition: Our team started the preparation phase by diamond grinding the entire substrate to remove the failed coating to create a mechanical profile. After all the grinding was completed we vacuumed the entire space to ensure a direct bond to the substrate. Finally, we installed a radial cove base within the restaurant kitchen flooring areas at 4” height and ¾” radius using: 100% solid epoxy mortar.
Products Installed: urethane cement flooring, as opposed to an epoxy kitchen flooring system, is very popular in the brewery industry as they offer several beneficial properties such as chemical, thermal shock, heat, and impact resistance. We started the installation process by applying our system base coat of urethane cement mortar. Before the mortar was given time to cure, we broadcast 20/40 mesh silica sand into it to create the desired anti-slip surface.
Once the mortar system was cured we swept away the excess sand and stoned the entire floor including the cove to remove any minor blemishes to create a consistent texture. Before applying our system grout coat, the next step was to saw cut around all joints and fill using flexible joint material. Once that was finished we applied our grout coat system, GP 3569; high-solid epoxy coating.
Finally, we applied our system topcoat of aliphatic urethane. It is a high solids, single component, aliphatic, moisture cure urethane, moisture-resistant industrial floor coating. This urethane coating cures to a high gloss and chemical resistant film equivalent to two-part urethane coatings. It also adds impact and abrasion resistance, chemical resistance, resists yellowing and is VOC compliant.
Before our food floor system, but after the mason did his remediation work.
Here is the substrate after mechanical abrasion, in preparation for our urethane cement flooring system
Our food flooring system uses a urethane cement flooring system. This floor includes a 4" radius coving to create a birdbath effect minimizing any bacteria infestation in the corners and making clean quick and easy.
Conclusion: We worked with the customer to create their unique protective flooring system with an anti-slip texture that allows for low maintenance. This brewery flooring installation will not only hold up against years of abuse but will prevent bacteria and mold spores from forming. Our brewery flooring system is perfect for anyone looking for an aesthetics upgrade while being compliant with all FDA and USDA codes.