INDUSTRIAL FLOORING AND CONCRETE COATING SOLUTIONS

When it comes to choosing the best industrial floors for your industrial facility, there are numerous factors to consider. Is it better to replace the entire floor and start fresh or to restore the existing floor? What design options are available, and are they customizable? How much downtime will there be for my staff between surface preparation, application, and returning to the work floor? What safety issues need to be addressed by the new floor coating? The process seems daunting, but it doesn’t need to be. As experts in industrial concrete floor solutions, Creative Maintenance Solutions, LLC, has the answers you need. Let’s begin by discussing the recommended types of industrial concrete floor solutions.

Decorative Quartz Epoxy Flooring is a seamless, resinous flooring system composed of 100% Solids epoxy and colored quartz aggregates. The decorative epoxy floor receives a 100% Solids epoxy topcoat, strengthening its impact resistance. When combining the high-functioning epoxy polymer resin with colored quartz granules, the result is a stylish, durable floor. Depending on the purpose of your business, from heavy manufacturing and machining to automotive plants and production floors, Decorative Quartz Epoxy Flooring can be installed in varying degrees of thickness.

Decorative Quartz Epoxy Flooring provides a sanitary, slip-resistant, long-lasting floor covering. This flooring solution can withstand high and heavy traffic, with optional skid, abrasion, and chemical-resistance that never interfere with your desired aesthetic. The design options are limitless - allowing you to customize floor patterns or embed your company logo directly into the floor. Many organizations use this opportunity to increase safety by designating driving lanes, storage areas, and pedestrian pathways throughout busy warehouses.

Within our Polished Concrete Guide, including the process is vital. Concrete floors obtain treatment with a chemical densifier that's purpose is to fill any gaps or natural pores in the material. This densifier acts as a hardener and penetrates any open space, creating a chemical reaction that hardens the surface. After the application and drying of the chemical densifier, the progressive grinding begins. Not unlike sanding wood, walk-behind polishing machines use finer grits of diamonds to bring out the intended shine and smoothness. Essentially, to measure polished concrete flooring, the higher the grade, the larger the aggregate and the finer the grit, the smoother the finish.

Vinyl Flake Epoxy Flooring creates a decorative look, resemblant of expensive granite - for just a fraction of the price. The multi-step installation process involves using a 100% solids pigmented basecoat. This epoxy base is broadcast with ornamental vinyl flakes and sealed with two topcoats of either urethane or 100% Solids clear UV-resistant epoxy. Because these enhancing flakes can be applied from full to sparse, the looks vary drastically. Unlike repetitive patterned floors, vinyl flakes suspended in the clear coating produce a random look.

Vinyl Flake Epoxy Flooring, different from flooring installed in sheets, creates a seamless surface is a multitude of textures. Like decorative quartz, this floor coating can be applied in varying thickness specific to your business needs. Decorative vinyl flakes range in size and color but are often used to replicate the appearance of high-maintenance terrazzo flooring. In addition to the diverse looks of Vinyl Flake Epoxy Flooring, other benefits include high load-bearing capabilities, the elimination of cracks that support mold growth, and the ability to withstand drastic temperature changes.

There are several different types of Epoxy Mortar Flooring solutions. Creative Maintenance Solutions offers Urethane Cement Mortar, Self-Leveling Epoxy Flooring, and 100% Solids Epoxy Mortar Flooring. Epoxy Mortar Flooring, highly regarded for industrial use because of its safety properties, aid against slips and falls with their added textures. Further enhancing employee safety, these floors bear heavy loads, protect against pitting and cracks, and offer overall protection. When choosing the type of Epoxy Mortar Flooring that is best for your industrial facility, it’s important to access the conditions the floor will be exposed to. The more extreme the condition, the more protection will be needed.

100% Solids Epoxy Mortar Flooring combines the epoxy with graded quartz or sand and then troweled into place. Used to completely level concrete slabs or patch holes and deformities, the heavy-duty flooring solution ranges in thickness. Epoxy mortar is also used to build smooth inclines and create essential floor-to-wall epoxy cove bases. A must-have in industrial facilities, floor-to-wall cove bases help keep these areas clean. Without the epoxy traveling up the wall, dirt, and debris easily get pushed into corners, creating a breeding ground for mold and bacterial growth.

Urethane Cement Mortar, under normal conditions, is hand troweling onto the concrete substrate. The design is prime for projects that require expeditious installation, while still providing extreme protection. Urethane Cement Mortar safeguards concrete, as well as steel and wood, substrates against impact, corrosion, abrasions, and thermal shock. Additionally, the texture of Urethane Cement Mortar lasts for the life of the floor, providing skid-resistance even in wet conditions. The durability of the physical characteristics of this flooring solution is about double those of concrete alone.

Self-leveling Epoxy Flooring also awards superior protection. The one-color epoxy system offered by Creative Maintenance Solutions preserves untreated concrete by warding off oil, dirt, grease, and salt. The easy to clean flooring system consists of an epoxy primer coat application, and depending on the flooring environment, is followed by a topcoat of 100% solids epoxy or urethane, combined with a UV and chemical resistant coating. Self-leveling epoxy flooring systems withstand high industrial traffic, aggressive chemicals, and thermal abuse. This flooring solution can be installed new or used to resurface deteriorated, worn-out flooring at significant cost-savings.

Polished Concrete

Like Epoxy Mortar Flooring, Polished Concrete comes in multiple options. The benefits of using polished concrete in industrial settings include stain-resistance, OSHA-approved slip-resistance, and reduced equipment and tire wear. Polished concrete requires little to no shutdown time, keeping your plant in business during the application process. Because of their tightly compacted surfaces, polished concrete floors require little maintenance. This compaction helps eliminate efflorescence or the surfacing of dust particles through the force of hydrostatic pressure. Efflorescence forces epoxies from the concrete surface and makes for costly repairs.

The reflective properties of polished concrete lead to improved lighting and reflectivity, saving money on utility bills while increasing safety on the job. Through the concrete polishing process, porous floors become tight and dense enough to repel contaminants such as oil and water. Polished concrete provides a lower-cost flooring solution from installation and application to the reduction in lifetime maintenance and upkeep. Environmentally friendly, LEED (Leadership in Energy and Environmental Design) certified polished concrete contains no VOC’s (Volatile Organic Compounds). LEED certification is a globally recognized symbol of sustainability achievement. Creative Maintenance Solutions uses the following types of polished concrete:

Salt and Pepper Polished Concrete, Salt and Pepper Polished Concrete looks like it sounds. A splattering of small aggregate remains exposed on the polished concrete surface, leaving a decoratively aged appearance.

Exposed Aggregate Polished Concrete: This polished concrete consists of larger aggregate. Referred to as heavily cut, the ground surface process is often used in the restoration of older concrete with limits on how much of the surface can be ground down.

Stained Polished Concrete: Staining polished concrete involves specific stains, properly applied by experienced installers, that chemically combine with cured concrete. This results in an antique look, the resemblance of tanned leather, or a natural stone appearance, depending on the style selected. Because the stain reacts chemically with the concrete below, it never peels, chips, or fades.

Exposing Aggregate

The term aggregate refers to a "broad category of coarse- to medium-grained particulate material used in construction, including sand, gravel, crushed stone, slag, recycled concrete, and geosynthetic aggregates." Different levels of sheen and ranges of aggregate exposure are achieved through the process of polishing concrete. Depending on the diamond grit used, the floor's appearance will be anywhere from matte to a mirror-like finish.

When the concrete exposure is ground and polished, but splattered with small pieces of aggregate, the floor is referred to as Salt and Pepper polished concrete. This finish gives the polished concrete floor an aged impression. Exposed aggregate polished concrete is when the polished concrete is more heavily cut, exposing more significant amounts of aggregate. This type of polished concrete flooring is often selected when the concrete substrate is broadcast with a custom aggregate.

Dyed Polished Concrete: Dyed polished concrete differs from stained polished concrete, in that, dyes do not react chemically with the existing concrete. Dyes offer a completely different visual effect. Available in an unlimited selection of colors, they allow for countless design options and multiple layers of color application to create a distinct look. Dyes can also be applied to concrete floors that have already been stained. Other variations of the dying process include mixing the color with acetone or water, creating an expanded selection of translucent colors.

Acid Stained Polished Concrete: Acid Stained Polished Concrete creates an elegant, professional floor with mottled colors dispersed throughout existing concrete. This method of decorative concrete, used in old and new concrete alike, is commonly used in industrial settings because of its transformative design and limitless coloring options. Acid Stained Polished Concrete resists the normal cracking and peeling often seen in conventional masonry stains and paints because it deeply penetrates the concrete substrate.

Now that we’ve covered the different types of professionally recommended industrial concrete floor solutions let’s talk about the most important factors to consider before making a final selection.

Overall Safety

At CMS, the old adage is true - Safety First. Creating a safe environment for your employees and visitors is imperative for any company. However, because of the increased danger and exposure to heavy equipment, moving parts, and grease and oil, safety must be your primary concern. Preventing slips and falls, and other work-related accidents save your company time and money.

For the safety of industrial workers, damaged concrete floor repairs must occur as soon as an issue is discovered. While updating floors improve the appearance of your industrial facility, their functionality is what boosts efficiency by providing a clean and safe flooring solution. Cracks and uneven or deteriorating concrete floors require immediate repair, whether by applying epoxy flooring, polishing the concrete, or sealing the concrete substrate.

Downtime

The nature of most industrial companies like manufacturers and production facilities require scheduled downtimes for routine maintenance and cleaning. Scheduling your industrial flooring project during this time is optimal and eliminates the need for multiple shutdowns. The flooring solutions recommended by Creative Maintenance Solutions minimize the disruption to your business by working around your schedule, proficiently completing your floors, and leaving you with a clean, safe work area.

Ask us about our low odor flooring options.

Chemical Spills

Take into consideration the type of industrial work environment you’re in. Are your floors exposed to chemical spills? For most businesses in this field, the answer here is yes. If so, choosing a chemically-resistant floor saves your bottom line. Any chemical can damage the surface of the concrete. Sometimes this process occurs slowly over time, and sometimes it happens instantly. Corrosive chemicals, both caustic and acidic, deteriorate uncoated concrete flooring, often breaking down the entire structure of the floor. Using a chemical-resistance flooring solution keeps production high by eliminating the need to fix damage from chemical spills continually.

Thermal Shock

Thermal shock occurs when floors are exposed to a drastic, sudden temperature change. Most commonly, this happens in facilities where a room is kept at a cool temperature (like a walk-in cooler or temperature-controlled production area) and then cleaned with extremely hot water or steam. The thermal shock results in cracks, bubbling, and peeling because the surface and substrate expand and contract at different rates. If this is a concern for your company, consult an expert to decide on the best protection for you.

Impact

In an industrial facility, it is guaranteed to have areas that are exposed to high impact. Whether from equipment traffic, heavy loads, or machinery, concrete slabs will crack and buckle. Evaluate your floor to determine the amount of direct impact it endures. The more pressure a porous, concrete floor is exposed to should result in a heavier, thicker flooring solution.

At Creative Maintenance Solutions, we understand that industrial facilities require specialized flooring and must follow regulations and safety codes to keep employees and visitors safe and secure. We train and study intensively to meet the needs of our customer’s industrial concrete floor solutions. We work with you directly, creating an industrial concrete flooring plan that prioritizes safety, enhances your look, and performs for years to come.

Creative Maintenance Solutions, LLC, offers an unmatched warranty and satisfaction guarantee. Because of our dedication to our customers and our confidence in our work, you can rest assured that your satisfaction is 100% guaranteed!

Additionally, we offer up to a 5-year limited Warranty on 1/8” thick floor systems. Our Warranty is unrivaled in the entire industry! We also offer up to a 3-year Warranty on Single Broadcast floor systems and up to a 1-year Warranty on Thin Mil coating systems. Our Warranty covers material performance and workmanship.

Creative Maintenance Solutions specializes in industrial concrete floor solutions and services to the following industries:

AIRPORTS

AIRCRAFT FACILITIES & HANGARS

MUNICIPALITIES

PRODUCTION FLOORS

INDUSTRIAL KITCHENS

MANUFACTURING PLANTS

FOOD PROCESSING PLANTS

WAREHOUSES

HEAVY MANUFACTURING

MACHINING

TOOL & DIE

AUTOMOTIVE PLANTS

We would love to help with your concrete flooring project!