1. Introduction
In the demanding environment of raw material treatment plants, flooring systems must withstand extreme conditions such as heavy loads, chemical exposure, thermal shocks, and abrasive wear. The Polyurethane Sanding and Anti-Slip Mortar Floor is engineered to address these challenges, offering a robust, durable, and safe solution for industrial applications. This flooring system combines advanced polyurethane technology with high-performance anti-slip mortar to deliver exceptional performance in critical zones where safety, hygiene, and longevity are paramount.
2. Technical Specifications and Composition
This flooring system integrates two primary components:
- Polyurethane Resin: A water-based, two-component polyurethane binder that forms a seamless, impermeable matrix. It acts as a high-strength adhesive, bonding the mortar layer to the substrate while providing chemical resistance and flexibility.
- Anti-Slip Mortar: A proprietary blend of graded aggregates (quartz sand, bauxite, etc.), cement, and additives. The mortar is formulated to achieve high compressive strength (>40 MPa), exceptional abrasion resistance, and a controlled surface texture for optimal slip resistance.
Key Technical Parameters:
- Thickness: 4-8 mm (customizable based on load requirements)
- Compressive Strength: ≥40 N/mm² (28-day cure)
- Flexural Strength: ≥8 N/mm²
- Abrasion Resistance: <0.02g loss (Taber Abraser, CS-17 wheel, 1000 cycles)
- Slip Resistance: COF (Coefficient of Friction) ≥0.6 (ASTM D2047)
- Temperature Resistance: -40°C to +120°C (continuous), 150°C (short-term thermal shock)
- Chemical Resistance: Resistant to most inorganic acids, organic solvents, oils, and deicing salts (refer to chemical resistance chart for specific substances)
3. Core Performance Advantages
3.1 Superior Durability
The system's hybrid composition-combining polyurethane's flexibility with mortar's rigidity-creates a synergistic effect that enhances load-bearing capacity and impact resistance. This makes it ideal for:
- High-traffic areas with forklift and heavy machinery operations
- Storage zones for abrasive materials (ores, minerals, chemicals)
- Processing areas with frequent equipment movement
3.2 Enhanced Safety
- Anti-Slip Surface: The controlled aggregate exposure in the mortar layer ensures consistent slip resistance, even in wet or oily conditions.
- Fire-Resistant Properties: Achieves Class B1 fire rating (DIN 4102) when installed with appropriate additives.
- Ergonomic Benefits: The polyurethane layer provides minor cushioning to reduce operator fatigue during prolonged standing.
3.3 Chemical and Environmental Resistance
- Broad Chemical Compatibility: Withstands exposure to common industrial chemicals, including sulfuric acid (up to 30%), and hydrocarbon solvents.
- Moisture Tolerance: Water-based polyurethane formulation allows installation on damp substrates (up to 10% moisture content) without delamination risks.
- UV Stability: Special UV-resistant topcoats available for outdoor applications or areas with high sunlight exposure.
3.4 Thermal Performance
- Maintains structural integrity across extreme temperature fluctuations
- Suitable for freezer applications (-40°C) and hot processing zones (up to 120°C)
- Thermal shock resistance prevents cracking from rapid temperature changes
4. Application Scenarios
This flooring system is specifically designed for raw material treatment plants handling:
- Bulk Materials: Ore processing, mineral sorting, aggregate storage
- Chemical Storage: Acid/alkali storage tanks, solvent handling areas
- Waste Processing: Recycling facilities, composting plants
- Food-Grade Applications: Grain silos, sugar processing, dairy operations
5. Installation Process
5.1 Surface Preparation
- Concrete Substrate: Moisture content <10%, compressive strength >25 N/mm²
- Surface Profile: Minimum CSP-3 (ICRI guide) achieved through shot blasting/scarification
- Repair Existing Cracks: Use epoxy injection or polyurethane mortar patching compounds
5.2 Application Sequence
- Primer Application: Water-based epoxy primer for concrete sealing
- Mortar Layer: Trowel-applied anti-slip mortar to required thickness
- Polyurethane Topcoat: Seamless, self-leveling polyurethane sealant with UV stabilizer
- Final Cure: Ambient temperature cure (20°C/72h) or forced drying (40°C/24h)
5.3 Fast-Track Installation
- Cold joints eliminated through continuous pour technique
- Traffic-ready in 48 hours (at 20°C)
- Minimal odor during/after installation (VOC <150g/L)
6. Maintenance and Lifecycle
6.1 Routine Care
- Daily cleaning: Pressure wash with mild detergent (pH 6-8)
- Monthly inspection: Check for surface abrasions or chemical staining
- Quarterly maintenance: Apply protective wax for high-gloss areas
6.2 Repair Procedures
- Localized repairs: Use polyurethane mortar patching kits
- Full resurfacing: Grind surface to CSP-2, reapply mortar layer
6.3 Expected Lifespan
- Light Industrial Use: 10-12 years
- Heavy Industrial Use: 8-10 years
- Chemical Exposure Areas: 6-8 years with periodic re-topcoating
7. Compliance and Certifications
- Safety Standards: EN 13893 (anti-slip), ISO 13287 (thermal shock resistance)
- Environmental: LEED v4 compliant (low VOC emissions), REACH regulation compliant
- Industry Certifications: FM Global Approved, NSF/ANSI 51 (food zone compliant)
8. Comparative Advantages
| Feature |
Polyurethane Mortar System |
Epoxy Coatings |
Concrete Sealers |
| Flexural Strength |
8-12 N/mm² |
4-6 N/mm² |
2-3 N/mm² |
| Thermal Shock |
Excellent |
Poor |
Fair |
| Chemical Resistance |
Broad spectrum |
Limited |
Minimal |
| Installation Speed |
48h cure |
72h cure |
7-day cure |
| VOC Emissions |
<150g/L |
300-500g/L |
200-400g/L |
9. Case Study: Success in Chemical Processing Plant
A leading chemical manufacturer installed this system in their raw material unloading zone handling . After 36 months:
- Wear Rate: <0.1mm/year (measured by ultrasonic thickness gauge)
- Slip Incidents: Reduced by 82% (post-installation audit)
- Maintenance Cost: 1.2/m2/year(vs.4.5/m²/year for previous epoxy system)
10. Conclusion
The Polyurethane Sanding and Anti-Slip Mortar Floor represents the pinnacle of industrial flooring technology for raw material treatment plants. By combining advanced material science with application-specific engineering, it delivers unmatched performance in durability, safety, and chemical resistance. With minimal maintenance requirements and proven longevity, this system provides exceptional lifecycle value for demanding industrial environments. For facilities seeking to optimize operational efficiency while maintaining the highest safety standards, this flooring solution represents the optimal choice.
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