Process Floor Anti-Slip and Chemical Resurfacing
A worn, spalled process floor chipped out, rebuilt, and resurfaced with a chemical-resistant anti-slip system that drains and sheds washdown.
The challenge
A process floor wore smooth and spalled where product spillage and washdown chemistry attacked the concrete. The surface lost its texture and broke apart, leaving a slick, uneven floor that was both a slip hazard for the crew and an open place for product to soak into the substrate. Once the concrete is broken and porous it holds spilled product and washdown, which is a problem for a food and beverage environment, and the damage keeps spreading as the chemistry works deeper into the slab. The plant needed sure footing back, a surface that cleans down, and concrete that stands up to the product instead of breaking down under it.
Our approach
We chip out the failed and unsound concrete back to a solid base so the new work has something sound to bond to. We rebuild the spalled areas with a repair mortar to bring the slab back to profile and set the falls so the floor drains. Then we lay down a chemical-resistant floor system and finish it with an anti-slip profile. We grade the surface to drain and shed the washdown, give the crew sure footing where it used to be slick, and put a barrier between the concrete and the product so the slab stops getting eaten.
- Assess and mapWe walk the floor to find the worn-smooth and spalled areas, check where product and washdown are soaking in, and confirm the chemistry the floor has to stand up to.
- Chip out and prepWe chip out the failed and unsound concrete back to a solid, clean base and prepare the surface so the rebuild and the floor system bond.
- Rebuild spalled areasWe rebuild the spalled and broken sections with a repair mortar, bringing the slab back to profile and setting the falls so the floor drains.
- Lay floor and anti-slip finishWe lay down the chemical-resistant floor system over the rebuilt slab and finish it with an anti-slip profile for sure footing.
- Cure and return to serviceWe let the system cure, check the finish and the drainage, and hand the floor back ready for product and washdown.
The result
- Failed and spalled concrete chipped out and rebuilt back to profile without replacing the slab
- Chemical-resistant surface that stands up to the product and washdown instead of breaking down under it
- Anti-slip finish that gives the crew sure footing where the floor used to be slick, and a surface that drains and cleans down
- Floor restored by factory-trained and factory-certified Belzona applicators
Belzona systems used
In the field
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