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Food / pharma plant

Food and pharmaceutical plants need hygienic floors and walls that take hot water, cleaning chemicals and constant washing. Joints and grout lines must not trap dirt.

Food plant cut in section with steel vessels, the floor sloping to a drain under an orange seamless coating

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What this project needs, step by step

Basement wall and base slab of waterproofed concrete holding back ground water, with a waterstop in the wall-slab joint Waterproof (watertight) concrete For basements, water tanks, pools and sewage works, make the concrete itself resist water with a low water–cement ratio, an integral waterproofing admixture and sealed construction joints. This is for new pours; it cannot fix a structure that already leaks. 7 steps Food plant floor section: thick seamless screed coved up the wall, anchored at a drain channel, with steam and water. Food, beverage & chemical floors Dairies, bakeries, beverage plants, pharma and chemical areas need floors that resist hot water, steam cleaning, thermal shock and chemicals without tainting food. Polyurethane-cement screeds (PurCem, Ucrete) with coved upstands are the usual answer. 7 steps Floor section: flexible polyurethane floor over primer, coved up the wall and bridging a hairline crack in the slab. Polyurethane & elastic floors Polyurethane floors are tougher and more flexible than epoxy, can bridge fine cracks and, with the right seal coat, resist UV. Use them on crack-prone slabs, for comfortable decorative interiors, on balconies, and as PU-cement screeds where heavy wear and heat occur. 7 steps Factory floor tiles on orange epoxy bed and grout, a drain in the floor, and liquid dripping from a tipped drum Chemical-resistant tile grout and bedding Tiled floors and walls in food plants, dairies, labs, industrial kitchens, plant rooms and thermal or salt-water pools need epoxy bedding and grout that resist acids, cleaning agents and wash-down. These are specialist systems. 6 steps Tiled shower wall with orange grout lines, falling water, and a cartridge gun filling a joint Epoxy tile grout (showers, kitchens, hospitals) Two-part epoxy grout from a cartridge gun gives stain-resistant, easy-clean joints in wet rooms, kitchens, malls, hospitals and indoor pools. It is for interior use, and the tile face needs protecting during grouting. 7 steps Floor joint with steel edge angles and orange sealant over a foam rod, and a heavy wheel rolling towards it Floor joints in car parks, warehouses and roads Saw-cut, expansion and connection joints in floors that carry people, cars, forklifts or trucks. The sealant must take both traffic and movement, and the joint must be sized for it. 6 steps Bath against a tiled wall with an orange silicone bead where the bath rim meets the tiles, and a shower running Sanitary sealing (baths, basins, showers and kitchen tops) Silicone joints where tiles meet baths, shower trays, basins, WCs and kitchen worktops. Choose a mildew-resistant sealant that suits the surface, and reseal before water gets behind the tiles. 6 steps Concrete building facade half coated with a protective coating by a roller on a pole, with rain beading off. Protective coatings & water repellents for concrete Coatings and impregnations that keep water, chlorides and carbon dioxide out of concrete facades, bridges, car parks and repaired structures. Choose a clear impregnation, an anti-carbonation coating or a crack-bridging coating to suit the exposure. 8 steps Concrete sump in the ground with a continuous protective lining inside, holding liquid fed by a dripping pipe. Chemical-resistant protection (tanks, bunds, sewage) Linings and coatings that protect concrete and steel from acids, sewage gases, fuels and industrial chemicals in treatment plants, chemical tanks, bunds and manholes. The coating is chosen for the actual chemicals, concentrations and temperatures, on a strong, prepared substrate. 7 steps Section of an underground sewage manhole with pipes, step irons and a protective lining on the inside faces Sewage tanks, manholes & septic tanks Sewage and wastewater structures leak out, let groundwater in and are eaten away by aggressive effluent. Plug and rebuild the concrete, waterproof it, and add a chemical-resistant lining where the effluent is aggressive. 7 steps Section of an underground concrete water tank in wet soil, lined on the inside, with joint waterbars and a sealed pipe Underground water tank Below-ground tanks leak out when full and let groundwater or dirty water seep in when empty. Plug and repair, then line the inside with a drinking-water coating; on new tanks, build watertight concrete and joints first. 7 steps