Project Overview: 2,000 SF of Cement Urethane Flooring for Machine Maintenance Area
Existing Conditions: The customer had a pre-existing concrete slab with a very old coating system which was in considerably rough shape since it could not tolerate the current conditions. Such as; steam wash downs, heavyweight loads, and chemical attack, so we specified a urethane cement flooring system to replace it.
Preparation of existing condition: We identified all failures in the existing slab/coating, we then saw cut beyond the perimeter of each crack and removed all debris. Once removed, each depression was patched and filled with a rapid setting repair mortar. After all of the patching material was set, the entire surface was prepped using diamond grinder which creates the mechanical profile necessary to achieve a strong bond to the substrate.
Once the mechanical profile was established we vacuumed up the remaining debris and solvent wiped the entire area to remove any dust particles left behind. Before we could move on to the installation there was a 15 foot long 3-foot wide ramp that needed to be installed. There was an existing difference in elevation between an expansion joint where two slabs met.
The existing patch had delaminated due to intense forklift traffic and poor sloping. We removed the existing patch, mechanically prepared the area with hand grinders and primed it using Propoxy S 100% solids epoxy. After giving 2 hrs for a primer to dry we screened a propoxy and kretefill mortar to transition the elevation difference allowing a permanent solution.
Products Installed: The installation was rather quick and routine we Installed Prokrete SL ⅛ “ urethane cement slurry and broadcast to rejection using a 40/60 mesh sand for added anti-slip protection and impact resistance. Before we could topcoat the area we swept away any excess broadcast and stoned down any imperfections. Finally, the area was ready to receive the top coat of Propoxy S 100% solids epoxy which was specified to hold up against the intense forklift and foot traffic the area was exposed to.
Conclusion: The end result is a beautiful and durable urethane flooring system designed to hold up against extreme traffic and impact. This urethane flooring system will hold up exponentially longer than the previous coating system that was applied.