Process Floor Anti-Slip and Chemical Resurfacing
A worn, spalled process floor chipped out, rebuilt, and resurfaced with a chemical-resistant anti-slip system that drains and sheds washdown.
A job completed with Belzona. This describes what the Belzona system does and how it goes on, not a record of a specific project by this distributor.
The challenge
A process floor wore smooth and spalled where product spillage and washdown chemistry attacked the concrete. The surface lost its texture and broke apart, leaving a slick, uneven floor that was both a slip hazard for the crew and an open place for product to soak into the substrate. Once the concrete is broken and porous it holds spilled product and washdown, which is a problem for a food and beverage environment, and the damage keeps spreading as the chemistry works deeper into the slab. The plant needed sure footing back, a surface that cleans down, and concrete that stands up to the product instead of breaking down under it.
The Belzona approach
The failed and unsound concrete is chipped out back to a solid base so the new work has something sound to bond to. A repair mortar rebuilds the spalled areas, bringing the slab back to profile and setting the falls so the floor drains. Then a chemical-resistant floor system goes down, finished with an anti-slip profile. The surface is graded to drain and shed the washdown, the crew gets sure footing where it used to be slick, and a barrier sits between the concrete and the product so the slab stops getting eaten.
- Assess and mapA walk of the floor finds the worn-smooth and spalled areas, checks where product and washdown are soaking in, and confirms the chemistry the floor has to stand up to.
- Chip out and prepThe failed and unsound concrete is chipped out back to a solid, clean base and the surface is prepared so the rebuild and the floor system bond.
- Rebuild spalled areasA repair mortar rebuilds the spalled and broken sections, bringing the slab back to profile and setting the falls so the floor drains.
- Lay floor and anti-slip finishThe chemical-resistant floor system goes down over the rebuilt slab, finished with an anti-slip profile for sure footing.
- Cure and return to serviceThe system cures, the finish and the drainage are checked, and the floor goes back ready for product and washdown.
The result
- Failed and spalled concrete chipped out and rebuilt back to profile without replacing the slab
- Chemical-resistant surface that stands up to the product and washdown instead of breaking down under it
- Anti-slip finish that gives the crew sure footing where the floor used to be slick, and a surface that drains and cleans down
- Floor restored by factory-trained and factory-certified Belzona applicators
In the field
More Sugar & Food Processing projects
Evaporator Vessel Hygienic Lining
Corroded evaporator vessel rebuilt and finished with a smooth, cleanable lining for hygienic product contact.
Sugar Mill Floor Chemical-Resistant Resurfacing
Broken-down sugar mill process floor repaired and resurfaced with a chemical-resistant, anti-slip system built for washdown.
Syrup Tank Base Corrosion Seal
Corroding syrup tank chime rebuilt and the base-to-foundation joint sealed to keep moisture from working back under the floor.
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