Protenergy Food Processing Plant

Protenergy Food Processing Plant - Renovations - 1/4 Inch Urethane Slurry - Concrete Floor Topping Cambridge, Maryland

Protenergy Company processes, packages, and private labels a wide variety of food products for large food companies and grocery chains. The plant is located in Cambridge Maryland and was originally established and operated as a seafood fry plant for some decades prior to their acquisition. The plant renovations were significant, basically gutting all existing equipment and placement of an entirely new process and production equipment.

One of their first areas of concern was the existing brick floor layment; which had typical mortar joints. Mortar joints or any imperfections in a surface creates a place for moisture to stand increasing the likelyhood of biological contaminants. Likewise the new owners wanted to provide a safe / non-skid surface in order to prevent slips and / or falls by their personnel especially during wash downs, wet floors.

Their original intention was to replace all the brick with concrete – then afterwards adding a concrete topping. Pro Coat introduced an idea for value engineering; leave the bricks in place and install the concrete topping direct to the brick surface. Sherwin Williams has a product and surface prep process which is very effective – going directly over top of the existing brick surface. This process & system had been tried and proven from 8 or 10 years prior and especially prevalent in brewery facilities.

Pro Coat thoroughly cleaned and degreased the existing brick substrate. After cleaning they shot blasted the brick to provide an ICRI Level 3 profile. “Profile” is a degree of roughness which insures maximum adhesion and forms a mechanical bond between the brick and the concrete topping. Shot blasting is a Sherwin Williams requirement for all of their ¼ inch slurry “Fastop” systems.

Pro Coat used their Blast Pro shot blaster along with the Blast Pro Hepa Filter dust collection system.

Once floor prep was completed, Pro Coat started the application of the base urethane slurry system. After the proper mixing of the 3 component mix, the floor techs used a “cam rake” to screed the “slurry” material down to an exact depth of ¼ inch. Immediately after this material is applied, it is backrolled and then an aluminum oxide aggregate is broadcast directly into the top of the urethane surface. Aluminum oxide is one of the strongest aggregates used in the flooring industry – this provides for excellent non-skid surface as well as durability helping this floor to outlast those that are installed with sand or other lower quality aggregates.

Once this ¼ inch base coat is set – Pro Coat locked in the aluminum oxide by applying a top / grout coat which enhances the appearance and maximizes the floor cleanability.