F A C T O R Y
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CASE STUDY
When American company High
Performance Systems took on
the job of creating a HACCP-approved
seamless flooring system for a large
client food processing company producing
ready-to-eat food, it knew the dangers ahead.
Food processing plant flooring is unlike any
other because there are important state safety
rules and regulations at play, the company
says.” Not only does food processing flooring
require more attention than most, it is imperative
that the operation is run as efficiently
as possible to ensure no lost profits for the
client, as the longer the plant has to remain
inoperable, the more money that is lost.” The
urethane cement flooring system in place
had the typical amount of wear and tear
expected for a six-year-old floor. The project
encompassed three separate areas within the
company’s production space. Each space had
a different material as the subfloor and, as a
result, each subfloor needed its own specification
in respect to means of preparation and
materials installed. Here’s how the company
went about it:
SCOPE: Production area of 56 x 48 production
area, 20 x 32 new area and 42 x 42
freezer (all in feet).
1. Remove all existing brick and mudbed to
subfloor to ensure new floor had adequate
pitch to drain and sound foundation
2. Remove existing epoxy within the walk-in
freezer
3. Mechanically abraid all areas, to include
using wire wheels to metal panel flooring
with walk in and the use of PCD inserts
on the existing epoxies throughout
4. Diamond grind entire area using 30 grit
inserts to smooth any rough cuts from
PCD inserts and establish flat subfloor
with appropriate profile
5. Install keyways at pitch termination to
maintain a minimum of 1/2" of thickness
6. Install modified cement to create appropriate
pitch to drains
7. Install 1/4" keyways at remaining drains
and door terminations to ensure urethane
cement slurry thickness and eliminate any
trip hazards once floor was installed
8. Install 6" radial coving to existing FRP and
cant coving to any diamond plate walls
and existing stationary equipment
9. Install DTM epoxy primer to walk-in freezer
metal floor panels and walls to ensure
proper bond
10. Install elastomeric epoxy to walk-in freezer
to allow elongation during temperature
change of freezer
11. Install final coat of elastomeric epoxy to
ensure waterproof of panel seams and
wall to floor joints
12. Install cement urethane slurry to production
flooring over ground pitch material
13. Broadcast to excess using 40/60 mesh
silica to create anti-slip seamless flooring
14. Sweep and stone entire surface to ensure
even consistent texture
15. Apply system topcoat: urethane cement
coating to create seamless and sanitary
production floor system.
RESULT: A HACCP and FDA preferred flooring
system with appropriate pitch and removal
of 90% angles using both urethane cement
product and elastomeric epoxies. With the
use of multiple chemistries, the design team
created a long lasting seamless floor system
for its client processing plant.
FLAWLESS
FOOD FACTORY FLOORS
Sika is a global leader in industrial flooring systems that can be formulated to resist anything
from lactic acid to heavy forklift traffic. Our Project References include many of the leading
names in New Zealand’s food and beverage industries. To arrange a no obligation quote on the
best solution for your operation, contact the experts in flawless factory floors.
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