URETHANE CEMENTS or EPOXY COATINGS FLOORING IN A
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Transcript URETHANE CEMENTS or EPOXY COATINGS FLOORING IN A
URETHANE CEMENTS or EPOXY COATINGS
FLOORING IN A BREWERY
Presented by
Norm Klapper
PEC – Boulder, Colorado
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
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
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
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
Second Street Brewing – Sante Fe
Epoxy with Decorative Quartz
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
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!
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
Concrete Preparation
SP5 and SP6 PROFILES
Concrete Preparation….cont.
All coatings require competent and
thorough surface preparation
Chemicals are supplements to 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
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
HAND TROWELED – EITHER
EPOXY or URETHANE CEMENT
Installation Details – Perimeter Key
Installation Details – Control Joint
Installation Details – Crack Repair
Installation Details – Expansion Joint
Installation Detail – Corner Expan. Joint
Installation Details – Metal Base Plate
Installation Details – Drain
Installation Details – Cove/Exp Joint
Installation Details – Spoon Cove Base
Installation Details – Cant Cove Base
Installation Details – Pipe Protrusion
Installation Details – Bolt Holes
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?
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
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
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 (>1015,000 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
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
Flexibilized ¼” Epoxy
COMPARISON of URETHANE & EPOXY TOPPINGS 1
(Assumes 1/4" Thickness, Flexible, Resin Rich Epoxies, Average Values)
PROPERTY
URETHANE
CEMENTS
EPOXY
TOPPINGS
Compressive Strength (psi)
11,000
5,200
Tensile Strength (psi)
1,800
2,030
Tensile Elongation (Filled)
N/A
3%
Bond Strength (psi)
>1000 psi ???
Impact Strength (in-lbs)
120
160
Shore Hardness (D)
85
75
4.75 : 1
5:1
Aggregate/Liquid Ratio
ASSUMPTIONS /
COMMENTS
Formula Dependant
Aggregate Filled
Proper Preparation
Aggregate Filled
By Weight
COMPARISON of URETHANE & EPOXY TOPPINGS 2
(Assumes 1/4" Thickness, Flexible, Resin Rich Epoxies, Average Values)
PROPERTY
URETHANE
CEMENTS
EPOXY
TOPPINGS
ASSUMPTIONS /
COMMENTS
212 °F
180 °F
Normal Operating
Conditions
400 °F (Hot Oil)
200 °F
Brief Excursions
Chemical Resistance
Excellent
Excellent
Acid Resistance
180 °F
140° F
Wear /Abrasion
Resistance
Excellent
Excellent
Service Temperature
Max Temperature
Crack Resistance
Thermal Shock
Moderate
Moderate to Good
Good
Excellent
Broadcasted Aggregate
Epoxy has greater
tensile elongation
COMPARISON of URETHANE & EPOXY TOPPINGS 3
(Assumes 1/4" Thickness, Flexible, Resin Rich Epoxies, Average Values)
PROPERTY
Application Techniques
Working Time
Cure Times
Ease of Installation
Installation Temperatures
Thickness
URETHANE
CEMENTS
EPOXY
TOPPINGS
Hand or Power
Troweled, Slurry
Hand or Power
Troweled, Slurry
10-20 Minutes
30 - 60 minutes
Temp Dependent
4-8 Hours
6-18 Hours
Temp Dependent
Difficult to Moderate Easy to Moderate
55°F - 80°F
38°F - 90°F
1/8" - 3/8"
1/8" - 3/8"
ASSUMPTIONS /
COMMENTS
Troweling more
challenging; Slurry
systems easier
Various Formulations
Any Thickness
COMPARISON of URETHANE & EPOXY TOPPINGS 3
(Assumes 1/4" Thickness, Flexible, Resin Rich Epoxies, Average Values)
PROPERTY
URETHANE
CEMENTS
EPOXY
TOPPINGS
Type
Resin-Rich
Top Coating
Opt. (Req’d for Aesth) Optional
Priming Required
Recommended
No (optional)
Life Cycle
Excellent
Excellent
Aesthetics
Finishes Dull
Finishes Shiny
Both can be top coated
$5.50 - $8.50
Flat or Concrete sloped,
1/4" Topping
Cost / SF (Installed)
Cost / SF (Installed)
$5.50 - $10.00
$8.00 - $15.00
Resin-Rich
ASSUMPTIONS /
COMMENTS
$8.00 - $15.00
5 : 1 By Weight
For Slurries or Aesthetics
Sloping to Drain
(1/8" in 10 Feet)
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
Anheuser-Busch
Urethane Cement – Screed Box
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)
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
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
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
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
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
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
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
Highly Decorative Flooring
Epoxy Quartz with Top Coat
Highly Decorative –
Epoxy Quartz with Top Coat
Highly Decorative
Epoxy Quartz with Top Coat
Second Street Brewing – Sante Fe
Second Street Brewing – Sante Fe
Winery Application
Large Scale Winery
Large Scale Winery
High Gloss Urethane
Three Floyds Brewing – Munster, IN
Three Floyds Brewing – Munster, IN
Three Floyds Brewing – Munster, IN
Three Floyds Brewing – Munster, IN
Before/After Coating
Slope to Drain
QUARTZ SAND ADDED FOR
AESTHETICS
Brewing is in my blood……
Personal history of family involved
in the brewing supplies business….
My Grandfather, Isaac Klapper
Supplied
many of the
local home
brewers in his
day
Circa 1925
Brooklyn, New York
Also known
for his Bootleg
“Bathtub” Gin
which my Dad
used to “run”
URETHANE CEMENTS or EPOXY COATINGS
FLOORING IN A BREWERY
Presented by
Norm Klapper
PEC – Boulder, Colorado
QUESTIONS?