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Industrial Floor Treatments (Stone) Ltd

 
  • Precision Engineering Facility
  • Brewery Flooring
  • Vehicle Workshop Flooring
  • Cheese Production Facility

Factory Floor Painting

Whilst we install a range of industrial floor finishes, the majority of our works comes into the category of factory floor painting. Almost without exception the type of floor paint we apply in industrial premises is a high build epoxy resin with a two coat application being equivalent in thickness to approximately 12-14 coats of ordinary single pack factory floor paint. Being epoxy resin based this floor paint will produce a finish that not only looks better but will out-perform standard factory floor paint many times over, particularly when subjected to abrasion and chemical attack whilst at the same time providing the following benefits:

Health & Safety - factory floor painting has a number of purposes and objectives. By using different colours to designate pedestrian gangways, forklift trucking aisles, pedestrian crossings, work stations, field areas, emergency exit routes, fire doors and hydrants, painting your factory provides a safer working environment for employees and visitors. We are often asked about colours in this type of situation and advise that whilst no specific colour schemes are required by law a popular choice is that green is perceived indicative of safety (pedestrian gangways), red as danger (forklift trucking aisles) and black and white as safe but potentially hazardous (pedestrian crossings) - this seems to work in most situations.

Operational issues - before undertaking factory floor painting we can restore the most eroded of floors, repair cracks and spalled joints as well as damage from years of mechanical or chemical abuse. This can reduce damage to forklift trucks as well as potential stock losses caused by working on a damaged or eneven floor.

Aesthetics - one of the principal benefits of factory floor painting is the vibrancy and colour that it produces. Clean, glossy floors have a dramatic impact on employee morale and enhance customer confidence whilst creating a more pleasant workplace environment than would be the case with dull, dirty or bare concrete floors.

Ease of cleaning - factory floor painting undertaken with epoxy resin or polyurethane resin floor coating systems produces floor surfaces that area easy to clean. Bare concrete floors attract and hold dirt whereas factory floor painting provides a barrier that makes cleanup faster and easier. Factory floor painting also helps to keep floors dry and safe and reduce the cost of sweeping and scrubbing.

Protection from wear - factory floor painting undertaken with epoxy & polyurethane resin systems protects the concrete which means that it will last longer than un-coated concrete. Vehicle traffic, particularly when combined with chemicals and other factors, can wear away the cement paste in concrete slabs and expose the aggregate. Factory floor painting will protect the concrete.

Light reflection - factory floor painting with a gloss finish will reflect more light than bare concrete. This provides greater visibility in your facility promoting safety and can reduce the need for auxiliary lighting.

Floor Screeding

Floor screeds are substantially thicker than floor paints, generally applied within the range of 2mm up to 9mm and can be loosely summarised as folows:

2mm - 3mm floors are usually self-smoothing pourable resins with either a gloss or matt finish. This type of floor finish is often applied in hygienic situations such as clean rooms, pharmaceutical production areas and laboratories. With such a thin section they are not suitable for application onto badly worn or rough floor surfaces and will follow the contours of the existing floor slab whilst providing a smooth operating surface for both vehicular and wheeled traffic.

4mm - 6mm floors are usually trowel applied resins selected for their physical and/or chemical properties. In heavy engineering environments the demands may be purely physical with a requirement for an abrasion and impact resistant floor finish. Not all epoxy resin screeds are the same with the resin:powder ratio varying typically varying from 1:4 up to 1:16. As a guide the more resin rich the screed the better it will perform in almost every suituation. To take this even further resin screeds with hard aggregates such as granite blended into the powder element will produce a floor screed with higher abrasion and impact resistance. We repeat - not all epoxy resin screeds are the same!

Decorative trowel applied epoxy resin flooring systems are also available by incorporating blended colour quartz aggregates to provide a fully functional floor with a bit more than a plain coloured finish.

6mm - 9mm - whilst this thickness is also covered by epoxy resin screeds it has become increasingly more popular to install polyurethane resin screeds. At increased thicknesses polyurethane resin screeds are more cost effective than epoxy resins and in most situationspossess impact, abrasion and chemical resistance properties well in excess of those provided by epoxy resins .

Food Grade Flooring

So what is Food Grade Flooring? A good question with no definitive answer. The term 'Food Grade Flooring' has been adopted into common usage with no clear definition established within any British Standard or Hygiene Regulations.

There are however a number of criteria that should be applied to floor finishes within a food preparation, production, manufacturing and packaging environment before entitling it to considered as Food Grade Flooring .

As a general guide a food grade floor finish should not taint food, be impervious through its thickness, be safe underfoot in both wet and dry conditions, be resistant to fatty acids, blood, animal waste, heat resistant, suitable for strong chemical cleaning, steam cleaning or sluishing with boiling water.

Process plant floors are also subjected to heavy forklift and pallet trucks. Most of the mechanical damage that occurs on the floor is adjacent to the floor joints, due mainly to impact resulting from solid wheeled vehicles.

Polyurethane resin floor systems possess many advantages over epoxy resin flooring systems and are highly recommended in commercial kitchens, meat, poultry, fish, dairy, brewing and soft drinks processing plants.

Polyurethane resin floors consist of waterborne polyurethane resins with cement and aggregates to provide fast cure, moisture tolerant systems with no strong odours or flammability issues.

They cure quickly in the cool and damp conditions typical of meat, poultry, fish and dairy processing plants and provide excellent chemical resistance and can withstand organic acids and common cleaning chemicals.

Polyurethane resin floors are extremely hard wearing and have excellent impact and abrasion resistant properties.

For many years polyurethane resin flooring systems have demonstrated excellent performance in wet food processing environments and in areas subject to severe thermal cycling, especially within theharsh conditions often present in meat, poultry, fish and dairy processing facilities.

Polyurethane resin floor screeds can be subjected to high temperatures and even steam cleaning so offer first class performance in these aggressive environments.

Epoxy Resin Floor Screeds

Epoxy resin flooring has been around for more than fifty years and is available in many formats, the most popular being:

Self-Smoothing High Gloss - epoxy resin floor toppings with a thickness ranging from 2mm through to 6mm. This type of epoxy resin flooring was introduced to the UK in the early 1980’s and found great favour in many industries including the automotive, aerospace, print, paper and packaging fields.

Epoxy resin floor toppings produce a very smooth surface and care should be applied when selecting them for areas that may be subject to liquid or powder spillages. Likewise the potential transfer of contamination underfoot e.g. oil from adjacent work areas should be taken into account. Often incorrectly referred to as ‘self-levelling’ this type of epoxy resin flooring is liquid applied and self-smoothing – undulations in the host concrete will not be eliminated and will be reflected in the final floor finish.

Trowel applied epoxy resin flooring mortar - 3 part systems consisting of a liquid resin and hardener that are heavily filled out with silica sand or similar to produce an epoxy resin flooring system with a typical thickness ranging from 4mm through to 6mm.

This type of epoxy resin flooring has been around for decades and was historically installed in the engineering and food manufacturing industries and the ratio of filler to resin can vary enormously from 5:1 for a resin rich chemically resistant flooring system right up to 14:1 for a budget system that will have significantly lower physical properties and chemical resistance.

Decorative trowel applied epoxy resin flooring systems are also available by incorporating blended colour quartz aggregates to provide a fully functional floor with a bit more than a plain coloured finish.

Although no longer as popular in food manufacturing or production areas due to the success of polyurethane resin floor screeds, there are epoxy resin flooring systems considered to be food-grade or food-safe that have been tested and certified by food research associations.

Polyaspartic Coatings & Broadcast Systems

A recent innovation is that of Polyaspartic resins.

These can be trafficked in as little as two hours which means that they are perfectly suited for application in critical areas where downtime is simply not an option.

A further benefit is that Polyaspartic resins can be applied at sub-zero temperatures without having any adverse effect on curing times.

With no odour or VOC's polyaspartic resin flooring can be installed in live public areas such as airports, rail stations, motorway service stations, leisure facilities, fast food outlets, theme parks, shops and supermarkets.

Summary

Whilst epoxy resin flooring is still the most widely utilised resin flooring technology throughout industry, the fast moving world in which we live has led to the development of alternative resin flooring systems with specific properties for niche markets and specific circumstances. Watch this space for further developments