Scratch-Resistant Polyurethane Heavy-Duty Anti-Slip Mortar Floor for Factory Buildings
Product Overview
The Scratch-Resistant Polyurethane Heavy-Duty Anti-Slip Mortar Floor is a high-performance industrial flooring solution engineered to withstand the harshest mechanical stresses, chemical exposures, and safety demands of factory environments. Combining a polyurethane resin matrix with high-hardness mineral aggregates, this system delivers exceptional scratch, abrasion, and impact resistance while maintaining a durable, non-slip surface. Ideal for heavy machinery workshops, automotive manufacturing plants, logistics hubs, and foundries, it ensures long-term durability, worker safety, and low maintenance costs.
Key Features & Benefits
1. Superior Scratch & Wear Resistance
- High-Hardness Aggregates: Embedded with quartz (Mohs 7) and corundum (Mohs 9) granules for resistance to:
- Metal Shavings: Withstands dragging of steel components, tooling, and forklift tines.
- Abrasive Debris: Repels sand, gravel, and welding slag without surface gouging.
- Heavy Traffic: Maintains integrity under 5-ton pallet jacks and 10-ton overhead cranes.
- Taber Abrasion Rating: <25 mg loss (CS-17 wheel, 1,000 cycles) (exceeds ASTM D4060 Class T10).
2. Robust Anti-Slip Performance
- Dual-Textured Surface:
- Base Layer: 6-8 mm polyurethane mortar with 1.2-2.0 mm coarse aggregates for R13 (DIN 51130) slip resistance.
- Top Layer: Broadcast with 0.5-0.8 mm fine-grit aluminum oxide for PTV ≥60 (dry/wet) (British Pendulum Test).
- All-Condition Grip: Maintains traction under:
- Wet/Oily Surfaces: Spills of hydraulic fluids, cutting oils, and coolants.
- Inclined Ramps: 15° slopes in loading docks or mezzanine access points.
- Freezer Environments: -30°C conditions with icy residues.
3. Heavy-Duty Impact & Load Tolerance
- Impact Resistance: Withstands 500 lb-ft (678 J) impacts (ASTM D2794) without cracking.
- Compressive Strength: ≥80 MPa (7 days) (ASTM D695) for withstanding dropped loads (e.g., 50 kg steel components from 2 m).
- Flexural Strength: ≥25 MPa (7 days) (ASTM D790) to resist cracking under vibrating machinery.
4. Chemical & Thermal Resistance
- Chemical Resistance:
- Acids: 10% sulfuric acid (pH 1), 5% (battery acid).
- Alkalis: 10% (CIP cleaning), 5% potassium carbonate (degreasing).
- Solvents: fuel, mineral spirits, and cutting fluids.
- Thermal Shock Tolerance: Endures -40°C to +150°C (e.g., forge floors, foundry casting zones).
5. Seamless, Hygienic & Low-Maintenance Design
- Cove Base Integration: Forms a 150 mm radius coved skirt with walls to eliminate dirt traps.
- Non-Porous Surface: Certified ISO 846 Class 0 (anti-fungal/bacterial) and ASTM E2180 (99.9% microbial reduction).
- Easy Cleaning: Supports high-pressure (1,500 PSI), hot-water (90°C) washing and solvent-based degreasers.
6. Fast Installation & Minimal Downtime
- Pot Life: 25-35 minutes at 20°C, enabling large-area applications.
- Curing Time:
- Light Traffic: 8 hours (walkable).
- Full Load: 36 hours (pallet jacks), 7 days (heavy machinery).
- Moisture Tolerance: Installable on concrete with up to 98% RH (ASTM F2170) via vapor-blocking primers.
Technical Specifications
| Parameter |
Specification |
Test Method |
| Thickness Range |
8-15 mm (customizable) |
ASTM D412 |
| Surface Hardness |
Shore D 80-85 (ASTM D2240) |
|
| Compressive Strength |
≥85 MPa (7 days) |
ASTM D695 |
| Flexural Strength |
≥28 MPa (7 days) |
ASTM D790 |
| Chemical Resistance |
Passes 90-day immersion in: |
ISO 2812-1 |
| |
- 10% Sulfuric Acid (pH 1) |
|
| |
- 10% Fuel |
|
| |
- 5% (pH 13) |
|
| Adhesion to Concrete |
≥3.5 MPa (pull-off test) |
ASTM D4541 |
| Slip Resistance (Wet) |
PTV ≥60 (British Pendulum Test) |
BS 7976-2 |
| Fire Rating |
A2fl-s1 (EN 13501-1) |
EN 13501-1 |
| Electrical Resistivity |
10-10 Ω·m (static-dissipative) |
ASTM F150 |
| UV Stability |
No discoloration after 2,500 hrs QUV-B |
ASTM G154 |
| VOC Emissions |
<30 g/L (compliant with LEED v4.1) |
California CDPH 01350 |
Applications
- Heavy Machinery Workshops: CNC milling, welding, and fabrication zones with metal shavings and oil spills.
- Automotive & Aerospace Plants: Assembly lines, paint booths, and engine testing areas with thermal cycling.
- Logistics & Distribution Centers: Loading docks, conveyor systems, and high-bay warehouses with forklift traffic.
- Foundries & Steel Mills: Casting floors, ladle handling zones, and slag processing areas with extreme heat and abrasion.
- Chemical Processing Plants: Storage areas for acids, alkalis, and solvents requiring chemical spill resistance.
Installation Process
- Surface Preparation:
- Diamond grinding to ICRI CSP 5 profile.
- Repair spalled concrete with rapid-setting epoxy mortar (min. 5 mm depth).
- Primer Application:
- Two-component polyurethane moisture-barrier primer (0.4-0.6 kg/m²) for adhesion and vapor control.
- Mortar Mixing & Pouring:
- Machine-mixed polyurethane mortar (1:1 volume ratio) with 20-minute working time.
- Poured at 8-15 mm thickness; troweled to a ±2 mm tolerance.
- Anti-Slip Broadcast:
- Immediately after pouring, broadcast coarse corundum aggregates (2.0 mm) for base grip.
- While tacky, apply fine aluminum oxide (0.8 mm) for top-layer texture.
- Finishing & Sealing:
- Remove excess aggregates; apply high-build polyurethane sealer for chemical resistance.
- Curing & Protection:
- Seal area for 10 hrs (foot traffic); 48 hrs (light machinery); 7 days (full load).
Certifications & Compliance
- OSHA 1910.22: Compliant for workplace floor safety.
- NFPA 704: Non-flammable system (fire-rated A2fl-s1).
- ISO 14001: Environmentally sustainable manufacturing.
- EPD Verified: Life-cycle assessment (LCA) data available.
Case Studies
- Caterpillar Inc. - Decatur, IL Plant (USA):
- 22,000 m² installed in 2021 across engine assembly and welding zones.
- Achieved zero scratches or delamination after 2 years of 24/7 operation with 10-ton overhead cranes.
- Tata Steel - Jamshedpur Plant (India):
- 15,000 m² system in foundry casting floors exposed to 1,450°C molten steel splashes and slag.
- Maintained PTV ≥55 and thermal shock resistance after 18 months.
Conclusion
The Scratch-Resistant Polyurethane Heavy-Duty Anti-Slip Mortar Floor is the ultimate solution for factory floors demanding uncompromising durability, safety, and performance. Its proven ability to resist scratches, impacts, chemicals, and thermal stress while ensuring worker safety makes it the preferred choice for global manufacturing leaders.
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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