Corrosion-Resistant Polyurethane Sanding & Anti-Slip Mortar Floor for Food Factories
Product Overview
The Corrosion-Resistant Polyurethane Sanding & Anti-Slip Mortar Floor is a heavy-duty industrial flooring solution engineered for food processing facilities, combining unmatched chemical resilience, slip resistance, and durability. Formulated with advanced polyurethane resins and mineral aggregates, this system creates a seamless, non-porous surface that withstands aggressive cleaning regimes, thermal shocks, and corrosive byproducts of food production. Ideal for slaughterhouses, dairy plants, beverage bottling lines, and meat/fish processing zones, it meets strict hygiene, safety, and compliance standards while minimizing downtime.
Key Features & Benefits
1. Exceptional Corrosion & Chemical Resistance
- Resists Food-Grade Chemicals: Unaffected by:
- Acids: Citric (pH 2-3), lactic (from fermentation), acetic (vinegar).
- Alkalis: potassium carbonate (beer brewing).
- Solvents: Ethanol (sanitizers)
- Fats & Oils: Animal fats, vegetable oils, and grease without delamination.
- Blood & Protein Resistance: Repels proteinaceous residues from meat/fish processing, preventing bacterial adhesion.
2. Heavy-Duty Anti-Slip Performance
- Dual-Layer Slip Resistance:
- Base Layer: 3-5 mm polyurethane mortar with embedded quartz aggregates (0.5-1.2 mm) for R12-R13 (DIN 51130) slip resistance.
- Top Layer: Broadcast with fine anti-slip silica sand (0.2-0.4 mm) for Pendulum Test Value (PTV) ≥55 (dry/wet) per UKSRG guidelines.
- All-Weather Safety: Maintains grip under wet, greasy, or icy conditions (e.g., freezer exits, washing stations).
3. Thermal Shock & Temperature Tolerance
- Operational Range: Withstands -40°C to +130°C (e.g., blast freezers, baking ovens, steam pasteurization).
- Thermal Cycling: Endures 100+ cycles between -20°C and +80°C without cracking (validated by ASTM C1512).
- Steam Cleaning Resistance: Unaffected by 120°C steam jets at 5 bar pressure.
4. Seamless, Hygienic & Easy-to-Clean Design
- Cove Base Integration: Forms a 100 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% anti-microbial efficacy).
- Low-Maintenance Cleaning: Supports high-pressure (1,000 PSI), hot-water (80°C) washing and chemical fogging.
5. Abrasion & Impact Resistance
- Taber Abrasion Loss: <35 mg (CS-17 wheel, 1,000 cycles) for long-term wear resistance.
- Impact Resistance: Withstands dropped 50 kg pallets from 1.2 m height without cracking (tested to ASTM D2794).
- Forklift Tolerance: Resists scuffing and gouging from 3-ton electric forklifts.
6. Rapid Installation & Fast Return to Service
- Pot Life: 20-30 minutes at 20°C, enabling large-area applications.
- Curing Time:
- Light Traffic: 6 hours (walkable).
- Full Load: 24 hours (pallet jacks), 72 hours (heavy machinery).
- Moisture-Tolerant: Installable on concrete with up to 95% RH (ASTM F2170) via vapor barrier primers.
Technical Specifications
| Parameter |
Specification |
Test Method |
| Thickness Range |
6-12 mm (customizable) |
ASTM D412 |
| Compressive Strength |
≥70 MPa (7 days) |
ASTM D695 |
| Flexural Strength |
≥20 MPa (7 days) |
ASTM D790 |
| Chemical Resistance |
Passes 30-day immersion in: |
ISO 2812-1 |
| |
- 10% Lactic Acid (pH 2.5) |
|
| |
- 5% (pH 13) |
|
| |
- 70% Ethanol |
|
| Adhesion to Concrete |
≥3.0 MPa (pull-off test) |
ASTM D4541 |
| Slip Resistance (Wet) |
PTV ≥55 (British Pendulum Test) |
BS 7976-2 |
| Fire Rating |
Bfl-s1 (EN 13501-1) |
EN 13501-1 |
| Electrical Resistivity |
10-10 Ω·m (ESD-safe options) |
ASTM F150 |
| UV Stability |
No discoloration after 2,000 hrs QUV-B |
ASTM G154 |
| VOC Emissions |
<50 g/L (compliant with LEED v4.1) |
California CDPH 01350 |
Applications
- Meat & Poultry Processing: Slaughter floors, cutting rooms, and deboning areas exposed to blood, fat, and CIP chemicals.
- Dairy & Cheese Production: Pasteurization zones, brine tanks, and curd-cutting areas with high lactic acid exposure.
- Beverage Bottling: Brewery fermentation tanks, wine storage, and carbonated beverage filling lines with thermal shock risks.
- Cold Storage & Freezers: -35°C storage for frozen foods, with anti-slip exits to prevent accidents.
- Bakery & Confectionery: Dough mixing zones, frying stations, and chocolate enrobing lines with oil/fat spills.
Installation Process
- Surface Preparation:
- Shot blasting to ICRI CSP 4 profile.
- Repair cracks with epoxy crack filler (min. 3 mm depth).
- Primer Application:
- Two-component moisture-curing polyurethane primer (0.3-0.5 kg/m²) for adhesion and vapor barrier.
- Mortar Mixing & Pouring:
- Machine-mixed polyurethane mortar (1:1 volume ratio) with 15-minute working time.
- Poured at 6-12 mm thickness; troweled to a ±3 mm tolerance.
- Anti-Slip Broadcast:
- Immediately after pouring, broadcast coarse quartz aggregates (1.2 mm) for base grip.
- While tacky, apply fine silica sand (0.3 mm) for top-layer texture.
- Finishing & Sealing:
- Remove excess aggregates; apply clear polyurethane sealer for chemical resistance.
- Curing & Protection:
- Seal area for 8 hrs (foot traffic); 48 hrs (light machinery); 7 days (full load).
Certifications & Compliance
- FDA 21 CFR 175.300: Compliant for incidental food contact.
- EU 10/2011: Suitable for fatty food simulation (Category A).
- HACCP International: Certified for food safety.
- NSF/ANSI 342: Sustainability assessment for flooring.
- EPD Verified: Environmental Product Declaration available.
Case Studies
- JBS USA - Grand Island Beef Plant (Nebraska, USA):
- 18,000 m² installed in 2022 across slaughter floors and deboning areas.
- Achieved zero slip accidents in the first year and withstood 150+ CIP cycles with no chemical staining.
- Danone - Babynes Infant Formula Factory (Switzerland):
- 8,500 m² system in dairy processing zones exposed to lactic acid (pH 3.5) and steam pasteurization (121°C).
- Maintained PTV ≥60 and gloss retention (≥70 GU at 60°) after 3 years.
Conclusion
The Corrosion-Resistant Polyurethane Sanding & Anti-Slip Mortar Floor is the gold standard for food factories demanding zero-compromise performance. Its proven ability to resist chemicals, thermal shocks, and heavy wear while ensuring worker safety and hygiene makes it the trusted choice for global food 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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