Sugar Mill Floor Chemical-Resistant Resurfacing

The challenge

A sugar mill process floor breaks down where spillage and foot traffic concentrate. Process liquor, sugar, and the acids and cleaning chemicals that come with washdown attack the concrete, and the surface ravels, pits, and loses its profile. As the concrete degrades it turns slick underfoot, which puts the people working the floor at risk of a slip. Left untreated the surface keeps breaking up, traps liquid in the low spots, and gives the housekeeping crew a floor that can no longer be cleaned down properly.

Our approach

We start by checking the floor to find the broken-down and unsound concrete and to read where spillage and traffic are doing the damage. We remove the degraded material back to a solid base, then rebuild the lost profile and fill the low spots with a Belzona 4000 Series concrete repair system. Once the substrate is sound and shaped to fall, we lay a chemical-resistant floor over it and broadcast an anti-slip aggregate into the surface so it grips when it is wet. The finished floor stands up to spillage and the chemicals that come with washdown, and it cleans down without breaking back up.

1. Assess and mapWe inspect the floor to find the broken-down and unsound concrete and read where spillage and foot traffic are driving the damage.
2. Remove and prepWe break out the degraded concrete back to a solid base and prepare the surface so the repair and the new floor bond properly.
3. Repair the concreteWe rebuild the lost profile and fill the low spots with a Belzona 4000 Series concrete repair system so the floor drains and sits flat.
4. Lay the chemical-resistant anti-slip floorWe lay a chemical-resistant floor over the sound substrate and broadcast an anti-slip aggregate into the surface so it grips when wet.
5. Cure and return to serviceWe let the floor cure and check it for coverage and grip, then hand it back ready for traffic and washdown.