URETHANE CEMENTS or EPOXY COATINGS FLOORING IN A BREWERY Presented by Norm Klapper PEC – Boulder,...
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Transcript of URETHANE CEMENTS or EPOXY COATINGS FLOORING IN A BREWERY Presented by Norm Klapper PEC – Boulder,...
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 AttackCIP daily wash down, caustics, chlorineBrewery waste productsYeast, carbonic acid
Protection from Mechanical Wear Impact Wear from Pallets, etc.Prevent cracking, abrasion
Why Coat Concrete Floors…..cont.
Provide Slip Resistance for SafetyMinimize wet, slippery conditions
AestheticsProvide an appealing and professional look
Cleanability & Maximize Service LifeMonolithic substrate and smooth transitions to
drains
Second Street Brewing – Sante Fe
Epoxy with Decorative Quartz
When to Coat?New Floors Best
Open areaNew Construction – BEST forContractorNo contaminationFloor, drains, etc. not compromisedNo equipment legs
Old FloorsWith existing coating?
REMOVE ALL – clean warrantyWithout 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 preparationMechanical
Diamond GrindingScarifyingShot BlastingCrack ChasingDetailing – 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 preparationChemicals are supplements to mechanical techniques
Acid EtchingChlorine 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 content28 Day RuleVapor barriers under new slabs - VERY importantMoisture in Concrete
Run Calcium Chloride TestPlastic Sheet Test – ASTM D4263Relative Humidity Meters (RH Meters)
High early concreteSteel 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
floorsBerms – created using same materials or filler
patch formulations – saves $ but takes longerCove or no cove? Spoon or “cant” type?
Urethane Cements / Epoxy Coatings
ALL providers of URETHANE CEMENTS have similar formulations
ALL have similar:Working TimeTemperature ResistanceChemical ResistanceBond Strengths to substrates
Urethane Cements / Epoxy Coatings
In Contrast, EPOXY COATINGS all have great variations in formulations
WIDE VARIATION in all characteristicsWorking TimeTemperature ResistanceChemical ResistanceBond Strengths to substrates
WHY THE CONTROVERSY?Great variations in epoxy formulations and
therefore varied application successMany offered non-resin rich, top-coated (grout-coated)
dry systems with high compressive strengths (>10-15,000 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 alternativesSimilar coeff. of thermal expansion to that of concrete,
less likely to delaminate under thermal shock
WHY THE CONTROVERSY….contEarly 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
ASSUMPTIONS / COMMENTS
Compressive Strength (psi) 11,000 5,200 Formula Dependant
Tensile Strength (psi) 1,800 2,030
Tensile Elongation (Filled) N/A 3% Aggregate Filled
Bond Strength (psi) >1000 psi ??? Proper Preparation
Impact Strength (in-lbs) 120 160 Aggregate Filled
Shore Hardness (D) 85 75
Aggregate/Liquid Ratio 4.75 : 1 5 : 1 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
Service Temperature 212 °F 180 °FNormal Operating
Conditions
Max Temperature 400 °F (Hot Oil) 200 °F Brief Excursions
Chemical Resistance Excellent Excellent
Acid Resistance 180 °F 140° F
Wear /Abrasion Resistance Excellent Excellent Broadcasted Aggregate
Crack Resistance Moderate Moderate to GoodEpoxy has greater tensile elongation
Thermal Shock Good Excellent
COMPARISON of URETHANE & EPOXY TOPPINGS 3 (Assumes 1/4" Thickness, Flexible, Resin Rich Epoxies, Average Values)
PROPERTY URETHANE CEMENTS
EPOXY TOPPINGS
ASSUMPTIONS / COMMENTS
Application TechniquesHand or Power
Troweled, SlurryHand or Power
Troweled, Slurry
Working Time 10-20 Minutes 30 - 60 minutes Temp Dependent
Cure Times 4-8 Hours 6-18 Hours Temp Dependent
Ease of Installation Difficult to Moderate Easy to Moderate
Troweling more challenging; Slurry
systems easier
Installation Temperatures 55°F - 80°F 38°F - 90°F Various Formulations
Thickness 1/8" - 3/8" 1/8" - 3/8" Any Thickness
COMPARISON of URETHANE & EPOXY TOPPINGS 3 (Assumes 1/4" Thickness, Flexible, Resin Rich Epoxies, Average Values)
PROPERTY URETHANE CEMENTS
EPOXY TOPPINGS
ASSUMPTIONS / COMMENTS
Type Resin-Rich Resin-Rich 5 : 1 By Weight
Top Coating Opt. (Req’d for Aesth) Optional For Slurries or Aesthetics
Priming Required Recommended No (optional)
Life Cycle Excellent Excellent
Aesthetics Finishes Dull Finishes Shiny Both can be top coated
Cost / SF (Installed) $5.50 - $10.00 $5.50 - $8.50Flat or Concrete sloped,
1/4" Topping
Cost / SF (Installed) $8.00 - $15.00 $8.00 - $15.00Sloping to Drain
(1/8" in 10 Feet)
Similar Installation TechniquesMixing – 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 minutesEpoxy Topping – open time, 45-60 minutes
CURE TIMESUrethane 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 & ColorsOptional Textures – determined by type
and size of sand mediaSilica QuartzAluminum OxideGrit / Mesh Sizes – from 16 to 30
Trade off between slip resistance and cleanability – VERY subjectiveStrongly suggest sample texture offered for
evaluation and approval purposesMaintenance and safety concerns need to be
balanced
Recommendations?
URETHANE CEMENTSHigher temperatures >220 degrees FChemicals at higher temperaturesNew construction for open areas due to less open
time for working/application
EPOXY TOPPINGSReasonable temperatures – 180 degrees maxCost concerns – easier to apply, smaller crews,
with usually somewhat lower installed costSingle step – finishes with higher gloss, no top
coat
Recommendations?
SUMMARYBoth 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
ConclusionsChoose 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 DecorativeEpoxy 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
Circa 1925Brooklyn, New York
Also known for his Bootleg “Bathtub” Gin which my Dad used to “run”
Supplied many of the local home brewers in his day
QUESTIONS?
URETHANE CEMENTS or EPOXY COATINGS FLOORING IN A BREWERY
Presented by Norm Klapper
PEC – Boulder, Colorado