Flooring System Solutions
150 years
More than a century of experience
150 years
30 Brands become one
Before Now
Coniroof®
CONIDECK®
Rheobuild® Masterflow®
Pozzolith®
MASTERSEAL®
150 years
The Construction Chemicals portfolio
Underground Concrete Repair &
Cement Additives Admixtures
Construction Protection Systems
Waterproofing &
Performance Grouts Flooring Systems
Sealants
Expansion Control
Tile Fixing Systems Wall Systems / EIFS Wood Protection
Systems
150 years
Challenges of an industrial flooring
Industrial Floor have to meet the very diverse requirements of various
industry for:-
Performance against
Impact and abrasion resistance
Chemical resistance
Thermal shock resistance
Desired Service life
Functionality
Buildability
Safety against slip, charge development, VOC
Ease of cleaning and good hygiene
Aesthetics
150 years
Problems of unprotected Concrete Floors
150 years
Problems of protected Concrete Floors
4/11/2016 UCRETE - General
150 years
Various flooring options
Dry Shakes floor hardeners (metallic/non-metallic)
Cementitious overlays
Solvent-free/Aqueous Epoxy self-smoothing floors
Polyurethane self-smoothing finish
PU Concrete self leveling screeds
150 years
Flooring solutions
The challenges
Providing floors withstanding tough environments,
e.g. in industrial, commercial, public buildings
Enabling highly flexible flooring solutions in terms of
functionality and design
Supporting fast floor installations esp. when buildings
are already in use
Ensuring a high level of indoor air quality
Our solutions
MasterTop® flooring solutions based on
polyurethane, epoxy and cementitious technologies;
for industrial and commercial buildings or the
education and health sectors
Heavy-duty Ucrete® flooring solutions geared to the
needs of the food & beverage, pharmaceutical or
chemical industries
The benefits
High durability of floors supports longer service lives
at lower maintenance needs
Faster, safer, more cost effective installations
150 years
Surface Hardeners from the Inventors
MasterTop # B E A C 1 1 # D :\ P H O T O _ C D \ IM A G E
Dry shakes
Iron reinforced toppings
150 years
MasterTop 100/410 - Dry Shake Floor
Hardeners
150 years
MasterTop 100/410 - Dry Shake Floor
Hardeners
150 years
Dry Shake Floor Hardeners
Areas of Applications
Storage Rooms
Workshops
Parking Areas
Garages
Basements
Warehouses
150 years
MasterTop 300 – Cementitious Topping
Metallic Aggregate reinforced cementitious floors
Applied as a wet application on green or cured concrete at
minimum 20mm thickness
High Abrasion & Impact resistant
Suitable for very aggressive environment
150 years
MasterTop 300 – Cementitious Topping
150 years
MasterTop 300 – Cementitious Topping
VIDEO
150 years
MasterTop 300 – Cementitious Topping
150 years
MasterTop 300 – Cementitious Topping
150 years
Epoxy Resin Floor protection
MasterTop 1200 epoxy
resin systems
MasterTop 1700 water
based epoxy systems
150 years
Limitations of Epoxy Resin floors
Non-Resilient / Brittle:
breaks easily under impact loading / anything falling on the floor can cause
epoxy floors to crack & debond.
Low resistance to abrasion:
reduced service life – requires frequent maintenance by re-coating
looses the glossy sheen soon after putting the floor in use – makes the floor look
patchy requiring a re-topping of epoxy to maintain the aesthetics
Thermal shock resistance:
Cannot resist hot water cleaning, debonds & cracks under exposure
150 years
Limitations of Epoxy Resin floors
In all, Epoxy floor require regular maintenance (depending upon the usage
every probably every 2 – 4 yrs)
The floor is unhygienic/unsafe – until it is repaired / re-topped again
Recurring cost of maintenance
Importantly, Maintenance demands production shutdowns – which is critical
150 years
150 years
Polyurethane Concrete Floors - UCRETE
Combination of strength & mechanical integrity of Concrete and
chemical resistance, thermal integrity, elasticity & durability of PU Resins
In use for more than 35 years in more than 50 countries.
More than 15 years experience in India.
Provides a prolonged maintenance free floor. Floors used in service for
even more than 20 years.
150 years
Ucrete – Polyurethane Concrete Floors
UCRETE flooring meets the very diverse requirements of various industry
for:-
Durability
Impact and abrasion resistance
Chemical resistance
Thermal shock resistance
Buildability
Slip resistance & Safety
Ease of cleaning and good hygiene
150 years
Ucrete – Impact & Abrasion Resistance
Heavy and hard wheeled traffic is widely
encountered in the various food &
beverage industries
Bins with small hard plastic wheels
Steel wheeled / hard PU wheeled
trollies
Pallet trucks
Often traffic is concentrated in corridors,
gangways, etc.
150 years
Exposure Condition
Impact & Abrasion resistance
Steel wheels, hard PU/plastic wheels, rubber
wheels
Harder the wheel, lesser they deform and
have a very small contact area
Thicker floors have better impact resistance and
generally last longer, especially in heavy traffic
environments.
The bigger the largest aggregate the better the
durability
The bigger the aggregate the better the scratch
resistance
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150 years
Ucrete – Impact & Abrasion Resistance
Low Modulus – resilient to impact loads,
does not crack or break
Withstands continuous trolley / fork lift
movements without abrading.
Class AR 0.5 as per BS 8204-2
(less than 0.05mm thickness loss)
150 years
Ucrete – Low Modulus
Ucrete typically has a modulus of @ 10
times less than a general concrete.
Low Modulus – resilient to impact loads,
does not crack or break
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150 years
Ucrete – Impact & Abrasion Resistance
Ucrete In Tyre Plant,
Performing since last 5 years without
maintenance requirement
150 years
Ucrete – Impact & Abrasion Resistance
6 years old Ucrete floor in a
Mechanical Plant in India
150 years
Ucrete – Impact & Abrasion Resistance
Stainless steel tube manufacturing
Picture taken after 4 ½ yrs.' of
installation
150 years
UCRETE – Air Craft Hanger
150 years
Ucrete – Chemical Resistance
A wide range of chemicals are commonly encountered in food & beverage
industries :-
85% Lactic acid lactic acid in milk
100% Oleic acid at 60 oC acids from oils and fats
50% Citric acid fruit acids
50% Acetic acid vinegar and sauces and cleaning
Alcohol wines and spirits, hand sanitizer
50% Sodium hydroxide for cleaning
30% Nitric acid for cleaning
15% Sodium hypochlorite for disinfection
150 years
Ucrete – Chemical Resistance
In pharmaceutical primary manufacture the range of chemicals and solvents
can be extensive:-
UCRETE is resistant to:-
Strong mineral acids eg. 30% HCl, 30% HNO3
Strong alkali eg. 50% NaOH at 60 oC
Solvents eg. Isopropylalcohol. trichlorobenzene, xylene
Strong organic acids eg, 50% Acetic acid,
Extensive chemical resistance tables are available.
150 years
Ucrete – Chemical Resistance
In engineering we meet chemicals too:-
UCRETE is resistant to:-
Battery acids eg. H2SO4
Mineral oils and synthetic oils
Solvents eg. in paint spray booths and for cleaning
Strong inorganic acids eg, pickling baths and for cleaning,
Extensive chemical resistance tables are available.
Anti-Static Version available
150 years
Ucrete – Chemical Resistance
26 years old floor
Magor Brewery, UK
150 years
Ucrete – Chemical Resistance
South India, Dairy Plant
Ucrete Installed in 2009
150 years
Ucrete – Chemical Resistance
Battery manufacturing plant
150 years
Ucrete – Thermal Shock resistance
The range of temperatures encountered
which can impact on the floor is extreme
In freezers down to – 40 oC
Under frying lines to + 150 oC
In CIP areas
Cleaning of vessels
Under pasteurisers
Under condensate lines
Various resin & tiled floors tend to fail under
thermal shock.
Ucrete Withstand Thermal stresses
prolonged hot water & steam cleanable
capable of performing from -40 degree C
to +130 degree C steam cleaning
150 years
Ucrete – Thermal Shock resistance
Ucrete resin system does not start to soften until
a temperature of 130 degree C is reached,
compared to other resins that start to soften at
around 55-60 degree C
Secondly, comparatively lower modulus of
Ucrete allows it to absorb the thermal stresses.
Also, an increase in the thickness protects the
bond line form the enormous stresses of an
extreme thermal shock.
The bond line under a 9mm tk. Ucrete floor
reach a temperature of 70 degree C within 2
minutes of impinging boiling water on the surface.
150 years
Ucrete – Thermal Shock resistance
150 years
Ucrete – Meat processing Plant
150 years
Ucrete - Milk Reception Bay
150 years
Ucrete – Thermal Shock resistance
150 years
Ucrete – Thermal Shock resistance
12 mm UD200 TZ
9 mm DP IF TZ UD200
6 mm DP HPQ(pu) UD200
DP HPQ
4 mm
MF MT
70 oC 80 oC 120 oC 130 oC
light steam full steam occasional 150 oC
150 years
Ucrete – Thermal Shock resistance
Freezer Temperatures
A 4 mm UCRETE floor can be used for freezer
applications down to -15 ºC
A 6 mm UCRETE floor can be used for freezer
applications down to -25 ºC
A 9 mm UCRETE floor can be used for freezer
applications down to -40 ºC
150 years
Ucrete – Cold Store Warehouses
150 years
Ucrete – Durability
Durability
Good substrate design and
detailing, especially edge
details, has a profound effect
on floor durability
Please see our “Design
Details” and “Design and
Preparation of Substrate”
guidelines
150 years
Ucrete – Faster Construction
BUILDABILITY
Moisture Insensitive
Does not debond when applied over
a high moisture content floor
Can be used for continuously wet
areas without the risk of debonding or
delamination
Can be applied to 7 days old
concrete / 4 days old polymer screeds
150 years
Ucrete – Faster Construction
BUILDABILITY
One can drill through a Ucrete floor the day after application to facilitate
the rapid installation of plant and machinery.
For work on a refurbishment project within a working facility Ucrete offers
a number of advantages
Can be applied to concrete with high moisture contents
Cures rapidly
Many grades can be installed and cured in a tight weekend or overnight
window, even at chill temperatures.
Solvent free and non tainting, even during application
150 years
Floor Design
Proper Design of reinforcement;
SFRC – steel fibre reinforced concrete
Possible to cast floor Upto 40 m of no joints space. (Typical panels 7.5 m x 40 m)
150 years
Floor Design
150 years
Floor Design
150 years
UCRETE industrial Flooring
Joints should be well positioned
…so where does this joint think it’s going?
150 years
Joint Sealant
Packing Rod
Good detailing at a channel edge for a long lived floor
150 years
Ucrete – Durability
150 years
Ucrete – Safer Floors
Ease of cleaning and good hygiene
150 years
Ucrete – Safer Floors
Both the food and pharmaceutical industries face regulation and
independent audit regarding hygiene.
In the pharmaceutical Industry:- Regulatory Requirements for GMP Areas
FDA (Federal Drug Agency)
“Current Good Manufacturing Practice for Pharmaceuticals” 4/1/87 Sub
Part C- Buildings and Facilities, 211.42© 10(i)-
‘Floors walls and ceilings of smooth hard surfaces that are easily
cleaned’
150 years
Ucrete – Safer Floors
Clean Room Environments.
Regulatory Requirements for GMP Areas
MCA (Medicines Control Agency - Europe)
“Guidelines on Sterile Drug Products Produced by Aseptic Processing”
(Europe) Part 1- Manufacture of Sterile Medicinal Products Premises.
17
‘In clean areas all exposed surfaces should be smooth, impervious, and
unbroken in order to minimises shedding or accumulation of particles or
micro-organisms and to permit the repeated application of cleaning
agents and disinfectants where used’
150 years
Ucrete – Safer Floors
Aseptic Facilities (Definition A1 – A4)
Product manufacturing controlled environment consisting of several zones
(A1 – A4) Materials Equipment and Personnel regulated to control
microbial and particulate contamination to acceptable levels (Aseptic does
not indicate a total absence of micro-organisms)
A1 – (Critical) Typically Class 100
A2 – (Critical Adjacent) Typically class 10,000
A3 – (Sub-critical) Typically class 10,000
A4 – (Controlled Area) Typically class 100,000
UCRETE resin floors are non dusting and are used in each of these areas
150 years
Ucrete – Safer floors
Explosion hazard
In both the food and pharmaceutical industries fine powders are
handled.
The pharmaceutical industry also uses a wide range of solvents, for
cleaning and in process
In spray painting areas solvents and fine organic pigments are
encountered
Organic powder / air or solvent / air mixtures can be ignited by sparks
caused by static electricity
An antistatic floor is an essential part of a system to control unwanted
static electricity
Ucrete offers a wide range of antistatic flooring
150 years
Ucrete – Hygienic floors
Hygiene considerations
Sanitising
floors must be able to be cleaned to a high standard, and be
resistant to the sanitising chemicals and procedures employed.
All UCRETE floors can be cleaned to food industry standards. Most
UCRETE floors can be cleaned to a standard comparable to
stainless steel
UCRETE does not support biological growth
150 years
Ucrete – Hygienic floors
Cleanability
Non-dusting, seamless flooring system – with minimal joints
Comparable to stainless steel – CCFRA report
Can continue through the drains
Does not support biological growth
150 years
Ucrete – Hygienic floors
Certification
HACCP – endorsed as food safe flooring surface
Eurofins – GOLD certified, Indoor air comfort certification
CFTRI – conforms to Global Mitigation standards laid down in US-FDA
175-300 for intended use for contact with potable water & aqueous food.
150 years
Ucrete – Safe floors
Slip resistance
With people working on wet or greasy floors it is clear that there is a risk
of slip incidents
Clearly specifying the right floor with the correct slip resistant profile is
one way of helping to prevent accidents
There are two widely used methods of measuring slip resistance
Pendulum tester to EN13036-4:
Tilting Ramp test to DIN51130
150 years
UCRETE MF/MFAS - 4 to 6mm tk smooth
finish
150 years
UCRETE UD 200 - 6 to 12mm tk, heavy duty
150 years
UCRETE IF
9mm thick iron armored floor
Reinforced with metal aggregates
Excellent resistance to high impacts &
abrasion
Suitable for most aggressive
environments
Matt Finished with surface profile
4/11/2016 69
150 years
UCRETE IF – Caterpillar Field Trial after 8 mths
Steel Plate Ucrete IF
4/11/2016 70
150 years
Ucrete – Safe floors
Slip Resistance
Slip resistance to DIN 51130
Ucrete MF – R10
Ucrete UD 200 – R11
Slip resistance to TRRL Pendulum, 4S
rubber, wet
Ucrete MF – 35
Ucrete UD 200 – 40-45
4S rubber
- 24 high slip potential
25 - 35 moderate slip potential
36 - low slip potential
150 years
Ucrete – Safe floors
Slip Resistance Floor
Texture
Green = Safe
Red = Danger
Optimum
Cleaning Footwear
Cleaning Footwear
Slip resistance is a balance
150 years
Ucrete – Textures
4/11/2016 73
150 years
UCRETE® MFAS / MFASC
4-6mm self-smoothing mortar
Service temperature: 60oC
Matt finish
Excellent mechanical resistance
even to steel wheels
Anti-static < 106 Ohm to EN1081
Anti-static < 5x104 Ohm to
EN1081
150 years
UCRETE® MFAS
Copper tape
UCRETE MFAS
4 - 6 mm
depending upon
specification
and earth linkage Scratchcoat primer to
seal substrate
150 years
UCRETE® MFAS
Copper tape
UCRETE MFAS
Conductive primer
4 - 6 mm
depending upon
specification
and earth linkage Scratchcoat primer to
seal substrate
150 years
Copper Taping for Conductivity
Copper tape shall be
provided such that no
point on a floor is at
distance of more than
6mtr from a copper tape.
Copper tape shall be
connected to minimum 2
earthing points in a room
Self adhesive 3M Copper
Tapes recommended
Fixing Copper tapes in Grids over Connecting Copper tapes to the
cured Scrath Coat earthing point
77 DD.MM.YYYY
150 years
UCRETE MFAS pharmaceutical clean room
150 years
UCRETE MFAS pharmaceutical pilot plant
150 years
Ucrete – Safe floors
Fire Classification
Bfl – s1 as per EN 13501 – 1:2002
Contributes to LEED credits
Anti-static versions available
150 years
UCRETE MFAS pharmaceutical clean room
150 years
UCRETE - Noodle manufacturing Plant,
South India
150 years
UCRETE – Air Craft Hanger
150 years
UCRETE – Pharmaceuticals
150 years
UCRETE - Chocolate Plant, North India
150 years
UCRETE - Beverage Plant, India
150 years
UCRETE - in Tyre Plant
150 years
UCRETE - Airline Catering
150 years
UCRETE - Tea Estate
150 years
UCRETE – Battery Plant
150 years
UCRETE - Packaged Foods, Gujarat
150 years
UCRETE - Cigarette Plant, Western India
150 years
UCRETE - Automotive plant, India
150 years
UCRETE - Pharmaceutical plant
150 years
UCRETE - Meat Processing Plant
150 years
UCRETE Benefits – Industrial Floors
Features Benefits
Joint less floor No joints means no place for dust to accumulation & for
bacterial growth – helps maintain hygiene
Hygienic Floors Does not support bacterial or fungal growth
Chemical resistance Does not detoriates under exposure to chemical attack,
including food acids (see chemical resistance chart)
Cleanable Tested for Cleanability at CFDRA – can be sanitized to a
standard comparable to stainless steel
Low Modulus Does not crack under impact – has better crack resistance
compared to natural stones & other resins
High Abrasion & wear Long service life
resistance
Thermally Stable Can resist hot water cleaning & steam cleaning
Conductive grade provides static charge dissipation for explosion hazard
area
150 years
UCRETE Benefits – Industrial Floors
Features Benefits
Low moisture sensitivity Does not debond under moisture - maintains bond
integrity
Fast Curing Floor can be used within 24 hours of application
Monolithic & Maintains a strong bond with floor
Homogeneous Forms a single dense & impervious layer throughout the
thickness
Long Service life No periodic floor maintenance cost & no shut downs for
floor repair & maintenance
Repair & maintenance generates dust & in a running
plant it can cause contamination
Track Record More than 35 years of successful use in more than 55
countries
150 years
