Choose The Right Plant Flooring

Avoid problems with the right choice in flooring.

By Dave Fusaro, Editor in Chief

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Assistant Brewing Manager Roseman is pleased with the results: “As great as these high-performance, long-lasting coatings look in the filtration room, the real bottom-line benefit is the reduced maintenance requirements that are yielding immediate savings. Washdowns are much easier to perform, especially for the ceiling, and because the floors resist abrasion, chemicals and impact, we are not interrupting production for repairs or recoating.”

In another brewery south of the equator, Grupo Bavaria SA decided to modernize its largest facility, in Duitama, Colombia, including all new floors in the receiving and staging areas. The plant already had a Stonclad HT flooring system from Stonhard (www.stonhard.com) in its bottling area, which had performed well for more than eight years. So Grupo Bavaria again selected Stonhard for the job.

Stonhard was contracted to install in the receiving and staging areas another Stonclad HT system, an ultra-corrosion resistant, epoxy mortar system that can withstand temperatures up to 200°F. Stonhard company reps also would re-seal the existing Stonclad HT floor in the bottling area with a layer of coating to renew its appearance and for added protection. In addition, a small nitric acid storage area in the brewing area was to be coated with Semstone 756, a fiberglass-reinforced lining system designed specifically to withstand nitric and chromic acids.

In preparation for the installation in the receiving/staging areas, the crew first removed an old epoxy flooring system using grinders and chisels. Then shot blasting equipment was used to prepare the concrete substrate for priming. The concrete was now free of all contaminants and foreign matter and was ready for a two-component, chemical-resistant primer.

Stonhard’s HT Primer is formulated specifically for use with Stonclad HT. It ensures a secure bond to the substrate, prevents draining of liquids from the flooring system and makes application of the overlayment easier.

Next, the three-component Stonclad HT was mixed and applied with a screed applicator to ensure the proper finished thickness (1/4 in.). Steel finishing trowels were used to compact and smooth the surface. After the floor cured, the surface was ground to remove any trowel marks or other imperfections and vacuumed to remove all dust particles. The Stonclad HT was then ready for a final coating of Stonkote HT4, a two-component, 100 percent solids epoxy coating with excellent resistance to high temperatures, acids, alkalies and most solvents. It improves cleanability, enhances appearance and increases chemical and abrasion resistance.

As with the new floor, the existing Stonclad HT in the bottling area was ground to clean and profile the surface and then coated with Stonkote HT4.

Then, it was on to an even more aggressive environment, the nitric acid storage tank area. Prior to installation of the Semstone 756 system, the substrate was prepared in the same fashion as for the Stonclad HT. Stonhard’s 800 Series Primer was used to ensure maximum product adhesion.

Once this layer was tack-free, a two component saturant base coat was applied with a notched rubber squeegee. Then, a fiberglass engineering fabric was laid into the liquids and overlayed with another coat of saturant. This time, a ribbed roller was used to ensure the fiberglass was thoroughly saturated.

After approximately five hours, the material had cured and was ready to be ground to eliminate any protruding fibers. After vacuuming the surface, the three-component mortar coat was applied. After that cured, a final two-component top coat was applied using a roller, completing the installation.

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