Foundry Floor Resurfacing in Milwaukee: Durable Solutions for the Toughest Environments

At Creative Maintenance Solutions, we specialize in high-performance flooring systems that are built to handle the most demanding environments. One of our latest projects took us to a foundry in the Milwaukee area, where we were tasked with repairing and resurfacing a heavily damaged aisleway. This area had experienced severe wear due to molten metal spills during material transport—a tough challenge that required a durable and long-lasting solution.

Here’s a behind-the-scenes look at how we approached this complex industrial flooring project and the steps we took to deliver a strong, reliable, and safe surface using a urethane cement flooring system.

The Problem: Damage from Molten Metal

Unique Challenges in Foundry Environments

Foundries are some of the harshest environments for commercial flooring. The constant movement of heavy materials, exposure to extreme temperatures, and risk of chemical or molten metal spills demand flooring systems that can take a beating without compromising performance.

In this case, molten metal had been spilled along a key aisleway in the facility during routine transport, causing significant surface damage to the concrete. These high-temperature incidents not only eroded the surface but also left it uneven and unsafe for continued use.

Our Process: Restoring and Reinforcing the Aisleway

Step 1: Shot Blasting the Substrate

Our first step in the resurfacing process was to shot blast the existing concrete surface. Shot blasting is a mechanical process that propels steel shot at high speed to remove contaminants, dirt, and deteriorated surface material. This step is critical in preparing the substrate and creating a clean, textured surface for strong adhesion of new materials.

Step 2: Patching the Damaged Surface

After shot blasting, our team performed a full inspection of the damaged aisle. Every crack, pit, and spalled area was carefully patched to create a stable foundation. We used durable, fast-curing patching materials to fill in voids and restore the profile of the floor. This step ensures that the new flooring system bonds effectively and can perform under the weight and abuse of daily operations.

Step 3: Grinding the Surface Smooth

Once the patching was complete, we mechanically ground the entire surface to achieve a uniform, smooth profile. Grinding removes any high spots and helps blend the patched areas with the rest of the floor, ensuring that the final surface is even and level. This preparation step is essential to the successful installation of the flooring system, especially in areas with wheeled traffic or heavy machinery.

The Solution: Urethane Cement Flooring System

Why Urethane Cement?

Given the extreme conditions at the foundry, we recommended and installed a urethane cement flooring system. Urethane cement is specifically designed for environments exposed to thermal shock, heavy impacts, and aggressive wear. It performs exceptionally well in foundries, commercial kitchens, chemical plants, and other industrial facilities where traditional concrete or epoxy systems may fall short.

Key benefits of urethane cement flooring include:

• Thermal Shock Resistance – Withstands sudden temperature changes from hot spills or equipment.

• Chemical Resistance – Resists damage from oils, solvents, and caustic substances.

• Heavy-Duty Durability – Handles impact from dropped tools, carts, and machinery.

• Moisture Tolerance – Bonds to damp substrates, making it ideal for industrial settings.

• Slip Resistance – Can be textured for improved traction and worker safety.

Final Installation

After preparing the surface, our crew applied the urethane cement flooring system throughout the entire aisle. This robust system not only restored the appearance of the floor but also reinforced it to better withstand the daily punishment typical in a foundry environment. The result is a seamless, long-lasting, and easy-to-maintain surface that will provide years of dependable performance.

Built to Withstand the Extreme

At Creative Maintenance Solutions, we pride ourselves on delivering flooring systems that are engineered to meet the specific challenges of each facility. For this foundry in Milwaukee, that meant creating a solution that could handle molten metal spills, heavy loads, and nonstop foot and equipment traffic. The combination of expert surface preparation, skilled application, and high-performance materials resulted in a durable and safe solution that meets the demands of an intense industrial environment.

Need Help With Your Industrial Flooring?

If your facility is dealing with worn or damaged flooring—especially in demanding environments like manufacturing plants, foundries, or warehouses—we can help. Our team has the experience, equipment, and solutions to restore your surfaces and keep your operation running safely and efficiently.

Contact Creative Maintenance Solutions today to schedule a consultation or learn more about our industrial flooring services. Let us help you build a foundation that’s ready for anything.