Chemical-Resistant Polyurethane Wear-Resistant Self-Leveling Mortar Floor for Cigarette Factories
Product Overview
The Chemical-Resistant Polyurethane Wear-Resistant Self-Leveling Mortar Floor is a specialized industrial flooring solution tailored for the demanding environments of cigarette manufacturing facilities. Combining advanced polyurethane chemistry with high-performance mortar technology, this system delivers exceptional resistance to chemicals, abrasion, and thermal stress while ensuring a seamless, hygienic surface critical for tobacco processing zones. Ideal for production lines, packaging areas, storage warehouses, and maintenance workshops, it addresses the unique challenges of the tobacco industry, including exposure to nicotine residues, solvents, cleaning agents, and heavy machinery traffic.
Key Features & Benefits
1. Superior Chemical Resistance
- Resists Nicotine & Tobacco Residues: Unaffected by nicotine tars, tobacco oils, and adhesive residues common in cigarette production.
- Solvent & Cleaner Resistance: Withstands frequent exposure to ethanol, and industrial-grade detergents without surface degradation.
- Acid/Alkali Tolerance: Protects against accidental spills of citric acid (used in flavoring), and weak alkalis.
2. Heavy-Duty Wear Resistance
- Abrasion-Proof Surface: Classified as T10 (EN 13892-8) with a Taber Abrasion Loss <50 mg (CS-17 wheel, 1,000 cycles).
- Impact Resistance: Endures dropped pallets, carton boxes, and machinery impacts without cracking or chipping.
- High Traffic Tolerance: Designed for 24/7 operation with forklifts, conveyor systems, and human foot traffic.
3. Thermal Stability for Process Flexibility
- Temperature Range: Operates from -30°C to +100°C continuously, accommodating cold storage areas (e.g., raw tobacco warehouses) and heated processing zones (e.g., tobacco expansion chambers).
- Thermal Shock Resistant: Withstands rapid temperature fluctuations (e.g., moving materials between -20°C freezers and +25°C production floors).
4. Seamless, Hygienic Design
- Cove Base Integration: Forms monolithic connections with walls, eliminating dirt traps and microbial growth zones.
- Non-Porous Finish: Certified ISO 846 Class 0 for anti-fungal and anti-bacterial performance.
- Easy-to-Clean Surface: Smooth or lightly textured options enable fast sanitation with low-pressure water jets or automated scrubbers.
5. Fast Installation & Low Downtime
- Rapid Curing: Walkable in 6-8 hours and fully load-bearing in 24-48 hours, minimizing production disruptions.
- Moisture-Tolerant: Installable on concrete with up to 8% RH (ASTM F2170), reducing substrate preparation time.
6. Safety & Ergonomics
- Slip Resistance: Optional R10-R12 textured finish per DIN 51130 to prevent slips in wet or greasy areas.
- Shock Absorption: 4-6 mm thickness reduces worker fatigue in standing workstations.
- Low VOC Emissions: Meets LEED v4.1 and GB 18582-2020 standards for indoor air quality.
Technical Specifications
| Parameter |
Specification |
Test Method |
| Thickness Range |
4-10 mm (customizable) |
ASTM D412 |
| Pot Life |
15-25 minutes at 20°C |
ISO 3251 |
| Compressive Strength |
≥65 MPa (7 days) |
ASTM D695 |
| Flexural Strength |
≥18 MPa (7 days) |
ASTM D790 |
| Chemical Resistance |
Passes 168-hour immersion in: |
ISO 2812-1 |
| |
- 10% Nicotine solution |
|
| |
- 70% Ethanol |
|
| |
- 5% Citric acid |
|
| Adhesion to Concrete |
≥2.5 MPa (pull-off test) |
ASTM D4541 |
| Impact Resistance |
225 lb-ft (305 J) (no cracking) |
ASTM D2794 |
| Fire Rating |
Bfl-s1 (EN 13501-1) |
EN 13501-1 |
| Electrical Resistivity |
10-10¹ Ω·m (static-dissipative) |
ASTM F150 |
| UV Stability |
No discoloration after 1,500 hrs QUV-A |
ASTM G154 |
Applications
- Production Lines: Cutting, rolling, and packaging zones exposed to tobacco dust and nicotine residues.
- Cold Storage: Raw tobacco and finished product warehouses requiring thermal shock resistance.
- Maintenance Areas: Heavy machinery workshops with oil spills and abrasive debris.
- Logistics Hubs: Loading docks and high-traffic corridors for palletized goods.
Installation Process
- Surface Preparation:
- Diamond grinding to ICRI CSP 3 profile.
- Repair cracks with low-viscosity epoxy resin.
- Primer Application:
- Two-component polyurethane primer (0.2-0.4 kg/m²) for moisture barrier and adhesion.
- Mortar Mixing & Pouring:
- Machine-mixed polyurethane mortar (1:1 volume ratio) with 10-minute working time.
- Poured at 4-10 mm thickness; self-levels to a ±2 mm tolerance.
- Finishing:
- Spiked roller de-aeration; optional broadcast of anti-slip quartz (0.3-0.7 mm).
- Curing & Protection:
- Seal area for 12 hrs (foot traffic); 48 hrs (light machinery); 7 days (full load).
Certifications & Compliance
- FDA 21 CFR 175.300: Compliant for incidental food contact (e.g., flavoring areas).
- ISO 22196: Anti-bacterial efficacy >99% against E. coli and S. aureus.
- CE Marking: EN 13813-compliant for industrial flooring.
- EPD Verified: Environmental Product Declaration available for sustainability reporting.
Case Studies
- China Tobacco Hubei Industrial Co., Ltd. (Wuhan Plant):
- 15,000 m² installed in 2021 across cutting, rolling, and packaging zones.
- Zero chemical staining or surface damage after 2 years of continuous nicotine exposure.
- British American Tobacco (BAT) - Bangladesh Factory:
- 10,000 m² system withstood 1,200+ cleaning cycles annually using ethanol-based disinfectants.
- Maintained slip resistance (R11) and gloss retention (≥60 GU at 60°) post-3 years.
Conclusion
The Chemical-Resistant Polyurethane Wear-Resistant Self-Leveling Mortar Floor is engineered to outlast the harsh realities of cigarette manufacturing. Its proven durability, hygiene, and safety credentials make it the preferred choice for global tobacco leaders seeking reliable, low-maintenance flooring that enhances productivity and compliance.
SPR is a rich experience in industrial building materials research and development and manufacturing enterprises, the company set product research and development, production, sales, technical service, design,plan construction as a whole, from the market itself and the actual needs of customers, special investigation, integration, implementation of integrated process operations, every step of the force.Strive for excellence, strive to provide customers with innovative system solutions and high quality products.
The company is located in Nanxiong High-tech Zone, Guangdong Province, covering an area of more than 20,000 square meters, with an annual output of 16,000 tons. In 2022, SPR and Guangdong Jianlang Hardware System Product Co., Ltd. reached a strategic cooperation in the form of equity participation, and set up a joint venture Guangdong Jianlang SPR Construction Engineering Co., LTD., to build the floor industry
Industrial chain one-stop service model.
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