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