TIPS & CONSIDERATIONS FOR

AVOIDING FLOOR FAILURE

IN THE FOOD & BEVERAGE INDUSTRY

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 With so many options to choose from, selecting
a fit-for-purpose flooring solution that
can withstand the operational demands
of food manufacturing, processing and
packaging environments can be challenging…

On top of this, rigorous health, safety

and hygiene standards as well as
budget constraints must be considered.

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 Yet the fact remains that floor failure resulting from
inadequate or cheap materials will have a negative
impact on food plant productivity.
Understanding the reasons or triggers that can lead to floor
failure in the food and beverage industry can help to prevent
such instances from occurring.

As they say: an ounce of prevention is worth a pound of cure!

This guide has been designed to offer practical TYPICAL REASONS FOR FLOOR FAILURE
advice on floor failure avoidance as well as to
WHAT RESIN FLOORING OPTIONS ARE AVAILABLE?
provide surface recommendations for clients
working in the food and beverage production, OPERATIONAL CONSIDERATIONS
processing and packaging industries.
TALK TO THE EXPERTS

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 Seams, joints, grout lines and cracks
REASON #1 in the surface of the floor are a

INADEQUATE breeding ground for bacteria, fungi,

molds, mildew and pests.
HYGIENE
All of these pose a threat to indoor
CONTROL environmental air quality as
well as any consumable goods
being prepared or processed on
the premises.

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 In extreme cases this can lead to the The addition of antimicrobial additives designed to
outbreak of foodborne illness, culminating inhibit bacterial growth will provide an added level
in death, irreversible damage to brand of protection. Additives, which are homogenously
reputation and costly lawsuits in the distributed throughout the resin material, can reduce
worst cases. surface bacteria by up to 99.9% between wash cycles.

Seamless resin flooring minimizes the risk of Unlike many antimicrobial alternatives,
microbiological contamination, providing a this protection remains active for the lifetime
monolithic, hygienic surface that is free from of the floor, even if worn or damaged,
the cracks or crevices where dirt, dust, bacteria offering clients’ a long-term, long-lasting
and even pests can dwell and breed. hygiene performance.

POLYGIENE®
Antimicrobial Additive
The silver ions are homogenously
1 distributed throughout the floor. 2 3
The silver ions migrate to
2 the surface of the floor.
1
The silver ions inhibits the formation of bacteria
3 on the surface by penetrating the cell membrane.

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 The organic acids, alkalis and salts
REASON #2 as well as hot oils, blood, sugars,

INSUFFICIENT lubricants and fats that form part

of food and beverage industry
CHEMICAL processes will invariably end up
on the floor and risk corroding the
RESISTANCE surface if it is not suitably protected.

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Ensure that any flooring material you are
considering comes backed by supporting
CHEMICAL RESISTANCE OF
data that demonstrates a sufficient level of
resistance to the chemicals to which it is likely
URETHANE RESIN
to be exposed within your workspace. 99 50% Sodium Hydroxide

99 20% Ammonia
The temperature of the chemical contaminants
99 Vinegar
or harmful substances will need to be
considered. For example, grease is fairly inert 99 50% Ethyl Alcohol

at room temperature but highly corrosive 99 10% Sulfuric Acid

when heated to high temperatures. 99 5% Nitric Acid

99 25% Citric Acid

On top of this, the nature of exposure to which
99 All-purpose Cleaner
the floor will be subjected is also important.
99 Mustard
This is typically categorized into three 99 25% Lactic Acid
types: immersion, intermittent spillage or 99 Red Wine
infrequent contact. 99 Beer

A full risk audit should provide an idea as to 99 Butter

how many chemicals or corrosive substances 99 Coffee & Tea

a floor is likely to come into contact with 99 Swine Urine & Faeces
throughout its lifetime. 99 Oils

99 Pickle Juice

99 Distilled Water

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 Food and beverage plants are
REASON #3 subject to punishing cleaning

POOR THERMAL and wash down processes that

can involve very hot water or
SHOCK even steam in order to remove
blood, grease and other
RESISTANCE unruly chemical contaminants
from the surface.

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However, the majority of Hard floors based on epoxy, Thermal cycling, whereby a
food and beverage plants vinyl ester or MMA chemistry floor’s temperature is slowly
operate at ambient room are not equipped to deal with or seasonally lowered or raised
temperatures and therefore thermal shock conditions and due to climatic or service
during cleaning and wash as a result can crack or conditions as well as periodic
down processes become delaminate when exposed to cleaning procedures, can also be
subject to thermal shock as extreme temperature swings, problematic. Again, improperly
the floor is suddenly exposed weakening the surface and specified materials will lead to
to temperatures in excess of invariably leading to the early problems including cracking
180 degrees Fahrenheit. onset of floor failure. and other damage.

WHAT IS THERMAL SHOCK?

All flooring material expands and contracts with changes in
temperatures. Only when this occurs at a rate significantly different
than the concrete substrate, does it lead to delamination, cracking
and other deterioration.

Thermal shock resistant flooring and coatings expand and contract at

a rate very similar to the concrete slab below, helping to ensure that
your seamless, hygienic industrial floor functions exactly as it should.

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 Another common cause of floor
REASON #4 failure within food plants is excessive

EXCESSIVE moisture vapor transmission through

the underlying concrete slab. Left
MOISTURE untreated prior to floor coating, this
can lead to blistering or de-bonding
TRANSMISSION of the final surface.

Although all concrete retains some degree of

moisture that is not all you need to be concerned
about. It is critical to determine the level of
moisture transmission the slab may be subject to,
particularly if it is low or on grade or located close
to high water tables.

If high moisture levels are anticipated, whether

residual or rising moisture, use of a flooring
system with high moisture vapor resistance, like
cementitious urethane, is critical to avoid failure.

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WITH VAPOR WITHOUT VAPOR
TRANSMISSION CONTROL TRANSMISSION CONTROL

3 3

2 1

1 Moisture Vapor 1 Moisture Vapor

2 Moisture Vapor Dissipates 2 Blistering Occurs

3 Floor Finish 3 Floor Finish

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 The weakest links in a typical floor
REASON #5 are the expansion and control

FAILURE TO joints as well as termination points

located around drains, doorways,
PROPERLY hot stoves or other details and
equipment. These construction
DETAIL THE details should be identified prior to

INSTALLATION construction to prevent undercutting,

cracking or de-bonding of the
surface from its substrate.

Expansion joints and control joints

are best saw cut after the floor
surface is in place. Termination
points should be keyed to prevent
lifting and undercutting.

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TYPICAL CONTROL JOINT TYPICAL EXPANSION JOINT
Joint Sealant
Flowfresh System
Flowfresh System
Joint Sealant
Min .5”
(12mm) Backer Rod
1/3 Depth
of Substrate Min .5”
(12mm) Typical Keyway

Existing Substrate Expansion Joint

Existing Substrate

TYPICAL TERMINATION AT STEEL TYPICAL BOTTLE COVE TO CURB

FLOOR DRAIN CROSS SECTION
Drain Cover Insulation Panel

Flowfresh System Sealant

Joint Sealant Flowfresh CM

(on curb)
Bond Breaker Tape
Flowfresh System
Steel Drain Liner
Existing Substrate
Typical Min .5” Existing Substrate
(12mm)
Keyway Typical
Min .5”
(12mm) Keyway
Min .5”
(12mm)
Min .5”
(12mm)

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 This is a big question asked by
WHAT RESIN industrial facilities managers
and plant operators working within
FLOORING the food and beverage industry.

OPTIONS ARE Resin flooring systems are available

AVAILABLE? in a wide range of shapes and
sizes and have been designed to
best meet the different working
areas within a food or beverage
plant - all of which will be subject
to different operating conditions.

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CEMENTITIOUS URETHANE METHYL METHACRYLATE (MMA) EPOXY

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 LOOKING FOR A
CEMENTITIOUS
URETHANE SYSTEM?
Ask your local Flowcrete
Representative about
our Flowfresh range.

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 Cementitious urethane systems are a popular choice

CEMENTITIOUS
for customers working in the food industry. A typical
urethane material used in this application comes in
mortar form combining cement and water-based

URETHANE technologies that exhibit a high cross-linked density,

making them ideal for abusive environments subject
to prolonged chemical attack.

99 Impressive impact resistance Urethane resin systems exhibit a thermal co-efficient

of expansion, which is similar to concrete. This offers
99 Resistant to thermal shock & cycling excellent benefits when installed directly over concrete
99 Bacteria resistant, non-porous finish in environments subject to thermal shock and thermal
cycling as it prevents the material from cracking when
99 Can contain antimicrobial additives subject to large temperature swings.
99 Hygienic seamless application
Cementitious urethane resin flooring solutions are
99 Slip resistant non-porous, preventing bacteria and mold spores
from surviving in joints or cracks typical of alternative
99 Moisture vapor resistance
flooring systems such as tiles or acid bricks. They are
also low odor as well as non-toxic and non-hazardous.

Urethane resin flooring can be adjusted to suit slip

resistance requirements to ensure safety underfoot.

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 Methyl methacrylate (MMA) systems offer food

METHYL
manufacturing and processing environments certain
performance advantages compared to alternative
resin materials, most notably their ability to cure at

METHACRYLATE an incredible speed and be installed at extremely

low temperatures.

(MMA) MMA resin can fully cure in just one to two hours,
making it an ideal choice for operational facilities
looking to minimize downtime and disruption as well
as fast-track new-build construction projects.
99 Cures in under two hours
99 Resistant to acids and alkalis MMA resin material demonstrates a high level of
resistance to a range of acids and alkalis. Although
99 Includes attractive flakes or aggregates MMAs have a unique odor during installation, the
99 Hygienic seamless application odor is harmless and can be minimized during
installation with proper ventilation.
99 Slip resistant
99 Well suited to non-processing areas

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LOOKING FOR A METHYL
METHACRYLATE SYSTEM?
Ask your local Flowcrete
Representative about
our Flowfast range.

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 LOOKING FOR AN
EPOXY SYSTEM?
Ask your local Flowcrete
Representative about our
Industrial Flooring range.

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 Epoxies are typically trowel or roller-applied, two or

EPOXY
three-component systems that are available in a wide
variety of colors. Epoxies can also be broadcast with
aggregates to deliver a slip-resistant finish.

Epoxies offer limited resistance to organic acids,

99 Attractive with varied finishes which are found in a large quantity of natural
99 Well suited to non-processing zones foodstuffs. However, epoxies offer no resistance to
thermal shock making them more susceptible to
99 Hygienic seamless application cracking and de-bonding in more rigorous food
and beverage environments.
99 Chemical resistant
99 Slip resistant Epoxy resin surfaces are a good choice for
non-processing zones of a food manufacturing
facilities such as packaging, maintenance and staff
break areas as well as corridors, lobbies and office
spaces, which are not subject to the same high
protection demands.

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 Understanding the most important
OPERATIONAL operational criteria and service
requirements of the facility or area
DEMANDS in question is critical to specifying
a resin flooring system that will best
meet your needs.

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DRY SERVICE CONDITIONS WET SERVICE CONDITIONS SLIP RISKS HIGH TEMPERATURE EXPOSURE

CHEMICAL RESISTANCE HEAVY IMPACT & TRAFFIC HYGIENE REGULATIONS AESTHETIC REQUIREMENTS

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 It is imperative that all floors in food manufacturing

SAFETY
and preparation zones, as well as staff break areas
and amenities, have a non-slip surface to prevent
slips and trips.

UNDERFOOT Considering the floor finish in terms of risk management

is even more critical in wet service environments,
ensuring the flooring system is tested under these
conditions to determine if it will provide the correct
level of safety.

In wet service environments, it is essential that flooring is

sloped leading to an efficient drainage system in order
to prevent the pooling of water and reduce the risk
of slips. This is best achieved by shaping the concrete
prior to the installation of a final floor finish.

Resin flooring is available in a range of textures and

can be graded with broadcast aggregates in order to
increase the anti-slip profile of the product.

It is important to note that coarsely textured surfaces,

such as positively graded resin systems, are more
difficult to keep clean, therefore a compromise may
need to be made where heavy slip resistance and
ease of cleaning are both of critical importance.

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Slips and trips
account for
an average of

20% Slips and trips in the workplace

result in an average of

21 SICK DAYS
of reported
injuries.
(× 10,000)

An estimated 391,000 people die Of all reported injuries from slips,

trips and falls in 2003-2004,
each year, world wide, due to falls.

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involve
There are just eight industries that make up 78% of
% fractures.
all injury claims resulting from slips, trips and falls.

MANUFACTURING (12%)
MEDICAL (12%)
CONSTRUCTION (11%)
In the United States,
RETAIL (10%)

$16,500
slips, trips & falls
TRANSPORT & STORAGE (10%)
account for

11
PROPERTY (8%)
ACCOMMODATION (8%)
OF HOSPITAL
EDUCATION (7%)
ALL OTHER INDUSTRIES (22%)
% BED DAYS
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 A zoning plan on the surface of the floor is a good

FLOOR
idea if a food plant has identified any areas at risk of
cross contamination or other hazards and is looking
to separate areas or zones by different processes or

ZONING & procedures or alternatively to designate different levels

of hygiene through a simple color coded system.

DEMARCATION Although there is no universal system or language

in place, pigmented flooring materials can be used

PLAN to designate walkways or hazard risks in line with

individual company policies and practices.

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 LOBBY AREAS

Flowshield Quartz Peran Floor Flakes

CORRIDORS

Flowfresh Ultra Flakes

DRY PROCESSING AREAS

Flowfresh MF

WET PROCESSING AREAS

Flowfresh SR Flowfresh HF Flowfresh SRQ

FREEZERS & COLD STORES

Flowfresh HF Flowfresh SR

WAREHOUSE SPACES

Flowcoat SF41 Flowcoat HTS

BATHROOMS & LOCKER ROOMS

Peran STB Broadcast Flowfast Quartz

DRAINAGE

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 The floor of a food processing plant can be a reservoir

HYGIENE
for microorganisms and a breeding ground for
bacterial types and strands that can contaminate the
working environment as well as the food product
leading, in instances, to severe consequences.

Statistically, flooring materials are usually more

microbiologically contaminated than any other inert
surface of food processing premises and therefore
great attention should be given to the choice and
application of a flooring material.

Resins containing antimicrobial additives, particularly

those that are homogenously distributed throughout
the resin material, can play a big role in a
contamination control strategy - reducing bacteria
on the surface of the floor by up to 99.9%.

Other ways in which to maintain a strong hygiene

barrier is to consider the transition between walls and
floors through the use of coving or cleanable sealed
junctions – again to eliminate any space that could be
susceptible to dust, dirt or bacterial build-up.

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FOODS MOST PRONE TO BACTERIAL FLOWFRESH CONTAINS POLYGIENE®;
CONTAMINATION ARE: A SILVER-ION ADDITIVE THAT REMAINS ACTIVE
FOR THE LIFETIME OF THE FLOOR, AND REDUCES
SURFACE BACTERIA BY UP TO 99.9% INCLUDING:
Meat products Soft cheeses

99 E-coli 99 Streptococcus Pyogenes

Poultry Raw shellfish 99 Pseudomonas Aeruginosa 99 Proteus Vulgaris
99 Staphylococcus Aureus 99 Enterococcus Faecalis
Eggs or food made Cold cooked 99 Salmonella Typhi 99 Listeria Welshimeri
with raw eggs seafood 99 MRSA 99 SARS Coronousitus

COMMON TYPES OF BACTERIA THAT CONTAMINATE FOOD ARE:

99 E-coli 99 Listeria Welshimeri 99 Streptococcus Pyogenes
99 Staphylococcus Aureus 99 Pseudomonas Aeruginosa 99 Enterococcus Faecalis
99 MRSA 99 Salmonella Typhi 99 SARS Coronousitus
99 Proteus Vulgaris

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 An effective cleaning and maintenance routine should

CLEANING &
be in place to preserve the aesthetic and performance
of the resin finish but more importantly to reduce the
risk of microbial contamination. Between wash cycles,

MAINTENANCE resin based flooring materials should, where possible,

be maintained in a dry state and at low relative
humidity conditions. Flooring must be sloped at around
1.5–2% in order to allow water to drain correctly.

Resin flooring will not be affected by most special

purpose cleaning materials, when these are used in
accordance with the Chemical Cleaning Manufacturers’
instructions. Specific cleaning instructions should also
be obtained from the resin flooring manufacturer.

A small spot test in an inconspicuous area is a

worthwhile precaution before applying any new
cleaning product. The cleaning procedure should
specify the type of equipment to be used, the type
of cleaning chemicals to be used and the frequency
of the cleaning and temperature.

It is important to note that cementitious urethane

systems are compatible with steam cleaning and hot
water washdown cleaning methods, whereas this is not
recommended for epoxy or MMA systems.

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 This guide has been produced to give an overview
of the resin choices available and factors to

TALK TO THE consider when specifying a resin flooring system

within the hygienic design of a food or beverage

EXPERTS processing facility.

Flowcrete has been successfully manufacturing and

supplying flooring material to the food industry
for over 30 years, securing high profile installations
at Unilever, Kraft, Coca-Cola, Nestlé, Cargill,
PepsiCo and Cadbury among other blue-chip food
manufacturers and agribusiness brands.

Flowcrete’s Flowfresh range has been specially

formulated for this industry and can play a critical
role in preventing microbiological build-up or
contamination. Based on cementitious urethane
chemistry, Flowfresh also incorporates Polygiene® –
a silver ion based antimicrobial additive, which
not only reduces surface bacteria by up to 99.9%
but continues to remain active for the lifetime of
the product.

Detailed recommendations and advice is available

from our network of regional technical and sales
representatives.

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