@YourSurface

HYGIENE AND SAFETY – NO COMPROMISE ALLOWED

Get inspired and informed by a variety
of specialists in the design and building
of food and beverage facilities

SELECTION
­G UIDE
EMPLOYEE
­SAFETY DESIGN
CONSIDERATIONS
A complete solution for Factors influencing slip Get informed about design essentials
surface finishes of a potential. How to manage for a hygienic, safe and functional
beverage facility the risk of slips? floor in food and beverage facilities
34 22 14

TRENDS HYGIENIC DRAINAGE

Customer preference, new technology and regulations A critical part of floor structure in
drive the design and interior finish selection food processing areas
42 28

ISSUE #2 2016
www.sika.com/food&beverage
THE FINISH LINE
In this issue of @Your Surface we discuss SAFE AND HYGIENIC SURFACES in FOOD AND BEVERAGE
PRODUCTION PLANTS. We’re pleased to present information about important issues related to this subject,
and at the same time showcase how Sika helps owners, designers and project managers select and install
the right floors, walls, ceilings, and other finishes for all their food processing and distribution needs.

Both building from the ground up or renovating an existing facility provides invaluable opportunities to
secure a company’s future success. Just as choosing the right food processing equipment is crucial to that
success, so is choosing the right flooring and installing it properly. Among many other things, it must be
hygienic, functional, tough, and safe to walk on.

Flooring is arguably one of the most abused of all surfaces in a food plant, or anywhere else for that matter.
Things, often heavy things, fall on it. Flooring has to take it and not crack or damage. Temperatures can
change from room temperature to beyond the boiling point, all in a matter of minutes or even seconds.
Flooring has to expand and contract accordingly and in concert with the substrate below to remain intact.
Pathogens pose the greatest risk in a food plant. Flooring has to eliminate or minimize crooks and crannies
where bacteria and viruses can hide, and at the same time be easily and thoroughly cleanable. Meanwhile,
employees rely mostly on their feet to get from one part of the plant to another. Flooring has to be designed
to prevent slips and falls, which can not only cause pain and injury, but can also lower productivity. Floors
need to be durable and last a long time. That’s because failures, even seemingly insignificant ones, can cause
expensive downtime, production losses, product contamination and, in the worst case, accidents.

While researching stories for this magazine, we spoke with numerous factory owners, production managers,
architects, designers, contractors and other stakeholders in the food production business to get their views.
We were rewarded not only by some valuable insights about the current state of affairs, but also by a look
into some important future trends.

We’ve attempted to condense these and other things we learned along the way into the body of this maga-
zine and balance them with how Sika helps today’s food processors select and install high-value flooring and
wall surfaces that feature sound hygiene, safety, functionality, durability and sustainability.

We take great pride in being one of the world’s leading manufacturers of high-quality finishes. We’re pleased
to introduce you to our profound commitment to the food production industry, and to our ability to serve it
effectively and efficiently. Our vast offering of sustainable design options covers a wide variety of applica-
tions, and with this we provide the know-how needed to help you make the right choice for both the present
and future, and install it on time and on budget.

Thank you for reading.

Sincerely,

Ari Tanttu
Business Development Manager TM Flooring
Sika Services AG

@YourSurface
Issue #2 | 2016 3
CONTENTS
#2 2016

7 44

14 22

7 Floor and ­interior ­design for food 44 Floor renovation in an ­operating

­processing and handling f­ acilities – ­facility – it’s about speed and product
a checklist safety
12 Hygiene and functionality – the main 48 Sika@work in food and ­beverage
design criteria in food plant flooring ­industry
design
50 Hygienically sealed details
14 Design considerations for ­hygienic
floors in food & ­beverage 52 Regulations and certification in food
­environments and beverage facilities
21 Keeping floors clean and food safe 54 Sika solutions and sustainability
22 Employee safety and slip-resistance 56 Sikafloor® solutions – a safe and
durable match for your specific needs
26 A good choice is an informed choice
64 Full range solutions for a watertight
28 Putting hygiene first and secure building envelope
31 Choosing seamless wall coatings for 66 Sika as a reliable and ­innovative
your plant partner in the ­construction of food &
beverage facilities
34 Selection guide – a complete solution
for beverage facility surface finishes
IMPRINT
40 System selection for beverage facility Editors’ address: Sika Services AG, Corporate Marketing, Tüffenwies 16,
CH-8048 Zurich, Switzerland, Layout and Design: Sika Services AG, Corporate
surface finishes Marketing, Marketing Services. Visit us on the Internet: www.sika.com

42 Powerful trends are driving floor and All trademarks used or mentioned herein are protected by law. All photo copy-
rights are owned by Sika except when mentioned. Reproduction is permitted
wall evolution in F&B with the written consent of the publisher.

@YourSurface
Issue #2 | 2016 5
 @YourSurface
6 Issue #2 | 2016
 FLOOR AND
There are a large number of surface
options available, particularly for flooring,
which can make choosing the right

­INTERIOR ­DESIGN
system a bit challenging. The following
checklist will hopefully assist you in the
decision making process for your facility.

FOR FOOD
FOOD SAFETY AND HYGIENE
Food safety and hygiene have become
visible on the radar screens of consumers,

­PROCESSING
industry, regulators, and other stake-
holders like never before. The Global
Food Safety Initiative (GFSI) along with
its various certification partners (FSSC

AND HANDLING
22000, BRC, SQF, etc.) has raised the bar
on food safety across all segments of the
industry from raw material suppliers and

­FACILITIES –
producers to distributors and retailers.

And for good reason. More than 200

diseases are known to be caused or

A CHECKLIST
carried by food. The World Health
Organization (WHO) reports that every
year thousands upon thousands of people
die from them. A 2010 global study, for
instance, showed an estimated 582
million reported cases of food illnesses
A dairy or beverage plant. A catering or industrial spanning 22 different diseases and
kitchen. A Winery. A slaughter house or fish causing approximately 351,  000 deaths.

packing facility. A bakery. A fruit and vegetable But there’s even more at stake. Unsafe
processing plant. A snack production facility. food poses major economic risks, espe-
cially in a globalized world. Take for
These are but a few examples of businesses that example Germany’s 2011 E.coli outbreak,
exist in the vast food processing industry. And which reportedly caused USD 1.3 billion in
losses for farmers and industries across
each of them has its own specific requirements Europe and elsewhere.
for flooring, walls, and other surfaces. Application As consumer preferences change, so
examples include freezers, bottling lines, raw must technology in order to keep up.
material processing and handling areas, packaging In response to the public demand for
more nutritious and better tasting food,
and storage areas, and the list goes on. industry has responded with a number
of milder processing and preservation
methods. These involve new processes
and machines that increase nutritional
and sensory properties while still making
sure that what reaches the table is safe
to eat and won’t make people sick.

But innovations cannot stop there. They

must also appear at the plant level.
The facility itself has to be designed

@YourSurface
Issue #2 | 2016 7
 and constructed in ways that prevent RESISTANCE TO INTENDED USE to withstand frequent, rapid, and often
any possibility of food contamination. Floor and wall finishes must be able to extremely wide temperature swings.
Choosing the right flooring, walls, and stand up to the demands of the space
other surfaces can help do this. Ideally, they’re in. In a slaughter house, as an MAINTENANCE
flooring should be seamless, and easy example, it’s not uncommon for heavy The maintenance program for any given
to clean, sanitize, and rinse thoroughly hooks to accidentally fall to the floor food production facility consists of many
to remove wash-down residues and any from time to time, or for heavy equip- aspects. Some involve machines. Others
viruses, bacteria or pests that might be ment to get knocked over. Flooring center on the physical premises. And
present. systems with low impact resistance are others still, and among the most impor-
the ones most likely to need frequent tant, involve cleaning and sanitation.
PERSONAL SAFETY repair or replacement.
Slips and falls are the most common Companies nowadays employ the HACCP
causes of injury at work, accounting for Aggressive cleaning agents are another (Hazard Analysis Critical Control Point)
an average 33% of total work injuries. In potential danger. Floors with low chem- approach across all major areas of produc-
the EU alone, over 20,000 million Euros ical resistance not only wear down tion. HACCP is a management system in
and 150,000 work days are lost annually faster, but can also create “traps” where which food safety is addressed through
from workplace mishaps. Depending on bacteria and viruses can hide. the analysis and control of biological,
the country, resultant financial costs can chemical, and physical hazards from raw
be as high as 1% to 3% of GDP. In storage areas, such as freezers and material production, procurement and
warehouses, flooring must possess handling, to manufacturing, distribution
Slip and fall injuries tend to occur most adequate mechanical resistance and and consumption of the finished product.
often in areas where meat, fruit, vege- substrate adhesion to handle the
table, fat and other residues are present. constant wear and abrasion from Cleaning and sanitation are key parts
In addition to keeping these residues frequent forklift and other traffic. of HACCP. The principles are common
from falling on the floor in the first place, Further stresses are caused by temper- to all food processing facilities, but the
companies can choose flooring that has ature shock. Some occurrences may be method and frequency of cleaning and
an optimum combination of grip and accidental, such as hot grease falling to sanitation will differ from one manufac-
wash-ability to keep employees safe and the floor during potato chip production. turer to another depending on the type
the facility nice and clean. Employees can Other occurrences, such as washdowns, of food that is produced and handled —
be protected further by the shoes and are intentional. These procedures use pre-cooked chilled meals vs dry goods
boots they wear, and by observing careful liquids that can often exceed 100°C, production, for instance.
working habits. or steam that can be a lot hotter. The
flooring system in place must be able Cleaning and sanitation of floors remains

@YourSurface
8 Issue #2 | 2016
HYGIENE AND SAFETY IN A MODERN FOOD
PROCESSING FACILITY IS NOT NEGOTIABLE
a specialty unto itself and must take being rinsed and removed, which in turn
into account numerous variables and the can increase downtime. High tempera-
occasional trade-off. Enhanced surface ture and/or high pressure hose cleaning
profile (rougher finish), for instance, will is another popular method, but not all
aid slip-resistance, but may also require floor finishes are able to tolerate extreme
more frequent and vigorous cleaning than temperatures or pressure. If aggres-
a perfectly smooth surface. Meanwhile, sive cleaning agents are used instead,
areas subject to oil and degreasing may they may cause damage to the floor,
need detergent solutions to be applied, depending what type it is. While tiles are
agitated and left in contact with the highly chemical resistant, the grout used
floor for a specified length of time before to connect them may not be. Synthetic

@YourSurface
Issue #2 | 2016 9
 resins, on the other hand, are resistant
to a wide variety of chemicals, but some
may suffer bleaching from prolonged
exposure to certain types, such as CIP
solutions.

DURABILITY
A durable floor is one that lasts a long
time, and one that resists deterioration
and loss of performance. Durable floors
begin with quality materials, good design
and sound workmanship. The whole floor
structure and each of its components
(sub-base, load carrying slab, screed
and upper protective layer) are inter-
dependent and work together to provide
the required levels of performance and
durability. If the ground and sub-base
fails, for instance, the concrete slab may
crack under heavy loads. Meanwhile,
if the coating has limited resistance be as simple as possible, and watertight of a floor, wall, or ceiling, it is always a
against chemicals, it may not be able coves joining floor edges to walls are good idea to separate the initial “hard”
to protect the slab underneath against important to facilitate cleaning. In addi- costs, including materials and installa-
deterioration. tion, floor joints, which tend to be the tion, from ongoing maintenance costs,
weakest parts of a floor, should be posi- which over time can easily exceed orig-
The life expectancy of any surface finish tioned away from high activity areas. inal procurement and installation costs.
is related to a combination of mechanical, In other words, while a less expensive
chemical and thermal stresses. These TOTAL COST ASSESSMENT floor may save a company some money
must all be taken into account when Comments such as, “If there is a budget at the outset, it may also result in a lot
designing and installing flooring that is crunch, core costs are the only ones that of hidden costs down the line. Flooring,
not underbuilt or overbuilt, but built just gets looked at,” or “Everyone is worried just like production machinery, should be
right for the application at hand. about the project being done on time seen as an equal component of the life-
and on budget,” are often heard during cycle cost of operating a plant.
FUNCTIONALITY AND DETAILS construction projects. Beware flooring:
Durability, ease of cleaning, slip resis- for the simple reason that it’s is one of
tance, and chemical resistance are all the last items to be installed, it runs SUSTAINABILITY
important functional aspects of indus- the risk of being downsized in value and Whether constructing or renovating, an
trial flooring, as is floor detailing (grills, scope in favor of other things, such as important thing to be mindful of is the
ramps, thresholds, etc.) and other equipment, which are considered to be volume of volatile organic compounds
attached structures. more critical. (VOCs) emitted by various floor, wall,
ceiling, and other finishes. Some emit
Floor drainage systems are an example. Yet, of all elements in a food processing more VOCs than others. The main advan-
Regardless of the cleaning method plant, flooring is arguably the most tage of choosing flooring materials that
chosen, high quality and well-positioned visible and one of the most vital contrib- meet or exceed low VOC emission stan-
drains are needed to remove chemicals utors to the success of a food operation. dards is it helps to keep air clean, which
and water from floor surfaces, and are an Skimping on installing proper flooring results in safer food production and
integral part of every cleaning and sani- because of unexpected budgetary a healthier working environment for
tation process. restraints or overruns could cost the employees.
operation dearly in the long run in terms
Other examples include gullies and chan- of slow processes, downtime, accidents, Materials should also feature low taint
nels, which should be configured to mini- and other things. transfer potential and little or no smell,
mize impacts on ergonomics, economics, especially during the application process.
hydraulics, and hygiene. Floor falls should When calculating the capital efficiency This requirement is more important for

@YourSurface
10 Issue #2 | 2016
some installations than others. Take, for QUALITY ASSURANCE knowledge and skills. Make sure the crew
instance, a production plant for infant AND CERTIFICATION you or your supplier has chosen has been
dry milk powder. In addition to using Floor and wall coatings, like most prod- properly trained and certified to install
HEPA filters to purify the surrounding air, ucts, usually come with a warranty. your particular system.
flooring will likely need to be made from Before purchasing, make sure you go
certified Clean Room Suitable Materials over the warranty in detail, including all As for the system itself, look for labels
(CSM). The ISO 14040:2006 environ- the fine print. indicating the product has been inde-
mental management standard for Life pendently certified to internationally
Cycle Assessment (LCA) is a good source Warranties are there to protect the buyer recognized quality standards, such as
of further information about these and against manufacturing defects. They the CE mark and HACCP. Also, make
other sensitive situations. are also an important selling tool for the sure the supplier has all relevant test
manufacturer. Make sure the company reports available, and fulfills all statu-
REFERENCES you’re dealing with has the ability to tory requirements. Further, ask if there
References are an invaluable part of back up its warranty obligations. Just as are options available for an extended
the decision making process, and every important, find out what kind of quality warranty for your system should you
flooring supplier should be able to provide management system the company desire them.
a list of satisfied customers. Call and visit has in place. ISO 9001, for instance, is
them. Nothing is a better confidence commonly used to assure uniformity in
builder than getting a first-hand look at manufacturing and adherence to a prod-
a quality installation of the floor you’re uct’s published specifications.
1
https://www.uni-due.de/~bys007/ressourcen/
pdf_dokumente/30/EU_30_05.pdf
considering for your facility. In addition to
building trust, you may also benefit from Look for relevant engineering certi- 2
http://www.who.int/mediacentre/news/relea-
picking up ideas that could improve your fications as well. Installing flooring ses/2015/food-safety/en/
own project and hygienic wall coatings is highly 3
http://www.slipnomore.com/slip_fall_stats
specialized work that requires specific

@YourSurface
Issue #2 | 2016 11
 Source: Arctica Ltd.
HYGIENE AND FUNCTIONALITY –
THE MAIN DESIGN CRITERIA IN
FOOD PLANT FLOORING DESIGN
The design and construction of new food and beverage
production facilities, or their refurbishment, are a complex
process and must successfully combine two main
disciplines: process engineering and architectural design.

Managing construction projects in and cost consultancy services to food joints, and falls. “Another key consider-
this highly complex industry requires manufacturing clients domestically and ation is always to ensure that any water
both experience and knowledge of the abroad. on the floor will flow quickly into appro-
manufacturing process. In food produc- priate drainage components”, says Niall.
tion facilities hygiene and food safety Architecturally, the most important
are also critical factors that must be issue at detail level is hygiene, says Niall. “Junctions and joints are the weakest
considered. “In practice, the most critical hygiene parts in terms of hygiene,” he notes.
issues are the junctions between “The less joints, the better.” The reason
Sika recently had the chance to different building components, particu- is that minimising the number of joints
discuss these and other issues with larly between floor finishes and stainless provides less hygienic risk and a reduced
Niall McQuitty, Director Architecture steel drainage components” he notes. need for maintenance.
and founder, and Damian Cleveland, "When designing floors one should not
Architectural Project Manager of Arctica only consider the flooring material, but The second most important issue in food
Ltd., a company based in Stamford, UK, all the other aspects as well", he says, facility floor design is personnel safety,
which provides architectural, engineering including gullies, channels, junctions, namely slip-resistance. Adequate grip for

@YourSurface
12 Issue #2 | 2016
shoes and boots reduces slips and inju- details are the most important issues ABOUT ARCTICA:
ries. In addition, good slip-resistance also now and will continue to be into the Originally founded in 2001 as an architectural
practice specializing in the food industry, Arc-
increases safer and smoother operations future. Reducing the number of joints is tica subsequently extended into process engi-
throughout the facility. vital so the ability to construct joint-free neering design and later into cost and project
floor slabs is a welcomed development.” management. Now they offer a multi-disciplin-
ary “one stop shop” for design and construction
The selection of floor texture depends of management of buildings for food process-
on the environment and the production Another important factor is shortening ing and industry. The company’s services range
processes; for instance the amount of the amount of time needed for a reno- from surveys and feasibility studies through to
building and process design, project manage-
food material from the process falling vation or new flooring installation; time ment and building contract management. With
onto the floor and how wet it is. is money. If a new installation could be more than 15 years of experience Arctica has
done over a weekend, all the better. developed a “can do” attitude and a passion for
accuracy and thoroughness.
It is worth remembering that the optimal According to Niall, Arctica welcomes
surface texture is very often a careful suppliers, such as Sika, who provide not
balance between the cleaning regime and only sound products, but also a consulta-
roughness. A rougher surface requires tive, time-sensitive, and service-based
more effort and energy to clean properly, approach in their activities.
and therefore more cost. However, this
may be necessary to ensure employee
safety, which of course is paramount.

Durability and the resistance against

stress are essential properties for
flooring. However, in many food factory
investments the real life-cycle cost
assessment for floors, namely mainte-
nance over time, is not considered to be
as important as the initial capital cost of
installation, and it should be.

A further consideration, and one where

increasing emphasis is now being put,
is aesthetics, most particularly colors,
for both functional and safety reasons.
“From a technical point of view, colors
other than the traditional red, such as
yellow and beige, are often now preferred
because food waste, dirt and other
contaminants can be more easily seen",
says Niall. Colour can also have a big
influence on the perceived quality of the
space too, with lighter and brighter colors
creating a much more positive working
environment than darker, flatter colors.

Meat plants, for instance, often now use

yellow instead of red so that food waste
can be very quickly seen and cleaned up;
salad and vegetable facilities now prefer
to use green or yellow.

“Hygiene will continue to be the most

important concern in food facility floor
design,” says Niall. “The junctions and

@YourSurface
Issue #2 | 2016 13
 DESIGN CONSIDERATIONS
FOR HYGIENIC FLOORS
IN FOOD & BEVERAGE
­ENVIRONMENTS

@YourSurface
14 Issue #2 | 2016
A functional and purpose-built floor is key to a safe and
hygienic production environment. Floors that are hygienic,
non-slip, easy to clean, and durable provide a safe and
attractive place to work.

Choosing and installing the right floor CONCRETE SCREED AND SLAB FLOOR FINISH
are critical to every work environment. Most substrates installed under a Floors in food and beverage manu-
This article looks at getting it right the hygienic floor are cement-based. These facturing facilities must meet several
first time — achieving satisfactory and are “in-situ” concrete structures installed different requirements. The surface has
long-term flooring in a food processing directly on the ground or suspended from to be easy to clean and must not support
environment. above. bacteria growth. The surface should
prevent slips and falls, and look appealing
SUBSTRATE DESIGN Screeds aren’t as thick as slabs and are as well. It should be robust enough to
Designing the substrate of a floor-just normally used to provide falls, or to handle all possible assaults from forklift
like all the other elements of a produc- create a new floor base in a renovation traffic, harsh cleaning chemicals, bumps
tion area including columns, walls, project. Fully-bonded screeds follow the and bruises, and thermal shocks.
equipment, and drains — depends a lot joint structure in the concrete substrate
on the overall layout of the building. All and are generally 75 mm thick or less. The regulation for floor surfaces in
elements together will affect how the Non-bonded screeds are thicker. the European Food Safety Directive
substrate is installed, and where floor 852/2004 states the following:
joints will be placed. Substrate slabs of good design are char-
acterized by the least number of joints “Floor surfaces are to be maintained in a
JOINTS possible, and placing them in low-risk sound condition and they must be easy
One of the reasons joints are needed in areas. to clean and, where necessary, disinfect.
a floor surface is to compensate for the This will require the use of impervious,
movement of the concrete slab below. FALLS, DRAINAGE AND JUNCTIONS non-absorbent, washable and non-toxic
In general, the size and flexibility of a Channels and gullies should be placed materials unless food business opera-
joint are determined by the amount the close to, but never under, processing tors can satisfy the competent authority
building moves. equipment. This will ensure they do that other material uses are appropriate.
their job while still remaining accessible Where appropriate, floors are to allow
Joints are typically one of the weaker to cleaning and maintenance. Moving adequate surface drainage.”
points in a floor. Take chemical resis- liquid across the floor to a drain is best
tance, for instance. It’s often consider- done using gravity created by floor falls A key concept behind this and the rest
ably lower in flexible joint sealants than — a gradual slope as the term suggests. of the regulation is simple: unless
it is in the surrounding floor finish. There are no set gradient standards for floors are properly maintained and
falls in food plants, but they generally sanitized, they can become a breeding
Joints can’t be eliminated completely, but range between 1:100 and 1:80. ground for harmful microorganisms. A
their number can and should be kept to common pathogen found on floors in
a minimum. They should be placed away Falls, drains, and junctions will affect the food premises, for instance, is Listeria
from areas that are subject to high traffic number of joints and how they’re posi- Monocytogenesca, which studies have
but close to areas where there are high tioned. A junction to a circular gulley, for shown can actually become persistent if
temperature variations (so as to allow instance, does not need a joint, while a not managed properly.
for resultant floor movement) and close junction between a long, wide channel
to high elevation points to avoid mois- and the floor-especially if exposed to This occurred in a tragic case in 2009 in
ture. They should also be detailed prop- high traffic, hot liquids, and movement Canada, where this pathogen remained
erly to stand up against stresses caused — will. Movement can be minimized undetected in production machinery and
by small hard-plastic wheels and passing through correct placement of concrete other parts of a meat processing facility
traffic, preferably by using prefabricated reinforcement under the channel. until it killed 22 consumers and injured
joint profiles. Meanwhile, falls can be simplified by dozens of others.
using longer channel drains.

@YourSurface
Issue #2 | 2016 15
 There are other examples. Granted, ANTI-SLIP PROPERTIES resistance they need. Some of the best
flooring surfaces are not food contact The most common method of providing known are the Pendulum Tester (EN
surfaces, and some may argue that for grip to new flooring is to broadcast aggre- 13036-4) and the Ramp Test (DIN 51130).
this reason not a lot of attention needs gate onto the top of the wet surface
to be paid to them. This attitude is very before it hardens. Aggregate varies in Flooring manufacturers have indepen-
risky, simply because microorganisms, if size and type and can create numerous dent test results based on these and
present on the floor, can potentially be profiles. The most common types are other testing norms. Ask to see them.
transported through water droplets, air silica, quartz, flint, and aluminum oxide. While all measures on paper are useful,
particles, or other means onto food prod- it’s still always a good idea to do a real-
ucts and the packaging materials that Transparent or pigmented topcoats are life roughness test in a small out-of-the-
contain them. applied over the aggregate to lock it way area of the floor you want to install
in. They prevent premature breakout, before going ahead with outfitting the
IMPERMEABILITY thereby extending the life of the anti-slip entire space.
It is critical that hygienic floors are surface. Some resin-rich mortar systems
easy to clean and free from bacteria come with aggregate already included, ODOR
growth. An important characteristic of but they’re generally not as rough as Bad smell can result in loss of products
a hygienic floor is impermeability, or lack broadcast systems. during production, and loss of sales at
of porosity. This feature is often best retail. Odors inside the plant can include
provided by dense resin-rich systems. Better slip resistance requires greater strong solvents, such as styrene and
surface roughness. This, however, makes other highly volatile materials, which if
Some resin system build-ups include the floor more difficult to clean. The inhaled can seriously affect employee
aggregate in the binder liquid. Caution is trade-off between the two is determined health.
required, however, in how much aggre- by what’s taking place on the floor, the
gate is used. That’s because if the ratio cleaning regime, and the type of contam- Solvents and other volatile organic
of aggregate weight to binder exceeds inants that are present. compounds (VOC’s) can leave a strong
8:1, pores in the resin surrounding the odor, some more than others, and the
aggregate particles won’t close properly. The degree of slip resistance needed will best safeguard against being exposed to
Topcoat sealants can be used to compen- likely vary from one part of the facility them is simply to not have them present
sate for this, but these tend to wear out to another. For instance, processing and at all. In fact, most food plants have
rapidly from normal traffic and abrasion cooking areas laden with oil and mois- prohibited use of any coating systems
resulting in a decrease in floor perfor- ture will have greater demands than containing solvents or ones that create
mance and food safety, not to mention a drier packaging and dispatch areas. There hazardous odors.
likely increase in maintenance and plant are numbers of tools available that can
downtime. help producers define the level of slip There are some coatings and surface
materials on the market that emit odors
while being applied, but becoming “non-
taint” after they’ve cured. In these cases,
it’s important to track the time it takes
for the product to set and become non-
tainting. Use only those materials that
have been independently lab tested for
their non-taint potential.

DURABILITY
Mechanical shocks and impacts, wear,
abrasion, exposure to chemical agents,
thermal shocks, high point loads, and
dragging and shifting pallets are exam-
ples of the many stresses affecting floors
in a food processing plant. Falls of heavy
objects, knives, hooks or other sharp
objects can lead to crack in the floor.

@YourSurface
16 Issue #2 | 2016
A DETAILED FLOOR SPECIFICATION IS
A PREREQUISITE FOR A SUCCESSFUL PROJECT

@YourSurface
Issue #2 | 2016 17
 The greater the thickness of the floor, When it comes to chemical resistance,
the greater its ability to provide good different floor coatings react differently
resistance to these and other assaults. to type, concentration, temperature,
Recommended thickness will depend on and exposure duration, and should be
a detailed assessment of the type and assessed individually. Among the most
magnitude of specific stresses the floor challenging are phosphoric or nitric acids,
will encounter. For resin-based flooring and caustic or chlorine solutions used to
in a food processing facility, 3 mm thick- clean production equipment, floors, and
ness is a minimum, but a thickness of walls.
6 mm or more is better, especially in wet
areas. For tile, thickness typically ranges Other hazards are elements that are part
anywhere from approximately 8.5 to of normal production, including lactic,
20 mm, but a minimum of 12 mm will citric, and acetic acids, blood, wet sugar,
protect any high load areas. oils, fats, greases, and others. It’s impor-
tant to note that even if the relative
amounts of these compounds are rela-
tively low, evaporation can increase their
concentration and corrosive properties.
Temperature in a plant can affect evap-
oration. It can also exert significant
stresses on its own. That’s because
temperatures in a food or beverage plant
can often vary widely and rapidly.

For instance, the temperature of the

floor adjacent to a freezer may range
from 0°C or below to an ambient 21°C
or higher. The flooring system must be
able to function in both conditions. What
is more difficult to deal is the thermal
shock, which is caused by a sudden and
large change in temperature, up to 100°C
or more and then back again, in a few
minutes or even seconds. Thermal shocks
can be caused by high temperature spills
from cooking, washing and cleaning of
vessels and pans. They can also occur
from hot CIP (cleaning-in-place) fluids
and hot water rinses that are drained
from production equipment and onto the
floor after high temperature cleaning and
sanitation.

Thermal shock can cause the flooring

system to crack and in some cases
de-laminate. To prevent this, the floor
should have a thermal expansion coef-
ficient close to that of the concrete
substrate below, good cohesive
strength, and a low modulus of elas-
ticity. Thickness of the floor also plays
an important part. The top layer should
be no less than 9 mm thick for water or

@YourSurface
18 Issue #2 | 2016
chemical discharges from +90°C and for
temperatures that are higher.

INSTALLATION
In food processing environments, espe-
cially when renovating, installing a new
floor can be a bit challenging. One reason
is the substrate may have a high mois-
ture content, which can affect adhesion.
Another reason is the substrate may be
contaminated with detergents and other
residues from production.

Dealing with higher than average mois-

ture conditions is usually a matter of
choice. Some flooring systems allow
higher moisture levels in the concrete GUIDELINES FOR A SUCCESSFUL FLOORING SELECTION
substrate than others, along with lower AND INSTALLATION
curing temperatures and shorter curing
times of only a few hours. The following are a few guidelines for ́́ How to construct details at junctions,
project managers and engineers respon- drains, coves, and walls
It’s important to choose a contractor who sible for specifying and installing floor ́́ How to ensure resistance of the floor
and wall coating systems:
has experience in dealing with these and finish to chemicals, temperature and
other variables, and whose workers are 1. Consult with the floor manufac­ thermal shocks
certified by the flooring manufacturer to turer and other suppliers early in the
́́ How to maximize long-term mechani-
design process and again throughout
install the products you choose. A good cal resistance, especially under high
the project. Coordination between the
result depends on good planning and manufacturer, concrete contractor,
wear and impacts
good cooperation of all parties involved and other suppliers can eliminate ́́ How to minimize equipment vibration
in the project. problems in the overall project. through use of elastic sealants
2. Select the surface texture for anti- ́́ How to use elastic sealants to con-
CONCLUSION slip purposes by considering worker nect metal drains and the floor slab
There are a number of reasons that floors safety as well as cleanup and sanita- ́́ How to build effective equipment
fail. One has to do with poor design and tion aspects. Test potential solutions bases
construction of the substrate, another is in a small test area first before decid-
that the floor finish is not suitable for its ing on the whole floor. ́́ How to maximize the hygiene of
planned use, a third is a poorly executed the flooring, i.E., Non-taint, easy to
3. Provide detailed specification for clean, and unable to support bacteria
installation and poor detailing. your flooring supplier, including exact
growth
material performance expectations,
It may seem ironic, but often it’s the installer qualifications, and sample ́́ How to access independent tests that
most expensive floors that fail the most. area selections and workplace limita- verify your requirements:
And when floors fail, it’s no small matter. tions. 5. Make sure that the flooring contrac-
Refurbishing and repairing a floor means 4. Specification and selection criteria tor has experience with similar jobs,
downtime, which in turn means lost should include: preferably in food industry, and has
revenue. On average, count on at least relevant installation certifications
́́ How to position drains
one week for a typical refurbishment 6. Ensure and promote clear lines of
́́ How to handle joints, ie., How to limit
of a floor, depending on the size and responsibility and communication
their numbers and how to place them
complexity of the repair. between the main contractor, in-
in non-critical areas
staller, floor manufacturer, and other
́́ How to design concrete substrates stakeholders.
An important feature of resin floors is
and screeds to handle stresses
they are continuous. And with a good
substrate design, the whole floor area ́́ How to make slopes drain effectively
can be made seamless, which greatly
improves hygiene. Minimizing joints

@YourSurface
Issue #2 | 2016 19
 further lessens hygienic issues while consultation he has provided to the DIN 51130 (Germany). Testing of floor co-
verings; Determination of the anti-slip property
improving durability and life of the floor. company on the subjects of cleaning and – Workrooms and fields of activities with slip
other matters regarding the hygienic danger, walking method – ramp test.
At Sika, we can help you get the right management of floors and wall systems.
J. Holah and H. L. M Levieveld: Hygienic d
­ esign
floor installed properly from the start. of food factories. 2011
Please don’t hesitate to contact us. In Fussboden Technik: Bodenanforderungen in der
addition to making your project happen REFERENCES Lebensmittelverabeitung. 01/2002
on time and on budget, we’re available H.L.M Levieveld, M.A Mostert and J. Holah:
Handbook of Hygiene Control in the Food Indus-
at any time to answer any questions you try. 2005
may have.
EN 13036 (British Standard): Road and ­airfield
surface characteristics – Test Methods. Part 4:
Sika wishes to acknowledge and thank Method of measurement of the slip/skip resis-
Mr. Timmerman for the excellent tance of a surface: The pendulum test.

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20 Issue #2 | 2016
KEEPING FLOORS CLEAN
AND FOOD SAFE
Hein A. Timmerman, Global Sector Specialist Food Care CIP
Timmerman says some areas, such as
at Sealed Air, and EHEDG* Board Member, comments on the CIP room, place the greatest demand
protocols and procedures for keeping floors in food and on resistant flooring. “That’s because a
beverage plants as sanitary and safe as possible. CIP installation uses strong chemistry
as a basic material — products contain
concentrated sodium hydroxide or potas-
sium hydroxide up to 50%, nitric acid up
to 62%, and the list goes on.” That list
The cleaning of floors in the food is the alcohol-based Diversey™ Divodes includes oxidative chemicals such as neat
industry differs from site to site, and FG VT29.” peracetic acid and sodium hypochlorite.
from process to process. Regardless, the
goal is the same: to maximize hygiene WET FOOD In CIP environments, temperatures can
and minimize food infection risks. Timmerman explains that in wet food reach up to 80°C in storage vessels. “The
processing areas, cleaning will be risk of spills is high,” explains Timmerman,
According to Hein A. Timmerman, water affected by the available cleaning equip- “but generally controlled cleaning floods
is one of the main culprits in a plant, ment and how the process equipment is are released over the flooring materials
particularly in a dry processing scenario. configured. “That’s because most of the and then exit through available drains. In
“It is known that water is a potential time, floors are cleaned together with automated process areas, certain valves
vector for spreading Listeria and creating the external surfaces of the machines,” will have specific sequences to release
the possibility of it being transferred he says. “Foam is often used and is high flows of diluted cleaning liquids
onto product,” he notes. “For this reason, applied to all external surfaces. At the onto the production floor during desig-
it’s important to keep the environment same time, adjacent floors are cleaned nated cleaning cycles.” He says other
as dry as possible.” with the same chemistry.” non-production areas are often cleaned
with scrubber driers. Though cleaning of
He goes on to say that maintenance The chemistry he’s talking about is floors may differ from one plant to the
workers should avoid using hoses, but usually an alkaline foam with seques- next, the one thing that remains common
this is not always possible given how trants or a chlorinated alkaline product. is the suitability and effectiveness of
certain plants are laid out and how they Periodically, workers apply formulations the cleaning chemistry. This even goes
function. “Break time cleaning should be based on phosphoric acids. “The contact down to the level of dyes and odorizing
carried out manually using buckets and time lasts around 10 to 20 minutes, elements — they’re not allowed.
cloths and sanitary wipes, rather than by giving workers time to use brushes to
pouring water over the production lines.” scrub away stubborn soils. The foams
In dry food processing environments, are then rinsed with pressurized water *The European Hygienic Engineering & Design
Group (EHEDG) is a consortium of equipment
floor cleaning is usually carried out at around 20 bar and with a flow rate of manufacturers, food industries, research
by brushing and vacuum cleaning. 30 – 35 l/m for each rinse hose.” institutes, and public health authorities. It
Periodically, wet cleaning is needed but was founded in 1989 with the aim to promote
hygiene during the processing and packing of
should be done with great care to ensure Drains, notes Timmerman, are not food products.
all residual cleaning water is fully drained cleaned at intervals like the rest of the The principal goal of EHEDG is the promotion
and the floor allowed to air dry. plant, but are cleaned continuously using of safe food by improving hygienic engineering
available equipment and cleaning prod- and design in all aspects of food manufacture.
EHEDG has recently published Guideline 44
“Often in facilities that produce high risk ucts. Disinfectants based on quaternary called “Hygienic Principles for Food Factories
foods, there are no drains at all. In these ammonium and amphoterics are partic- (2014),” which contains a chapter on hygienic
cases, powerful disinfectants are used ularly noteworthy, because they greatly flooring. Guideline 44 puts forward a number of
critical points that are crucial in assuring a high
that can evaporate quickly and that have help prevent Listeria. hygiene level in all areas of a plant, particularly
a specified non-rinse claim. An example high care areas, such as clean rooms.

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Issue #2 | 2016 21
 EMPLOYEE SAFETY AND
SLIP-RESISTANCE
Employee safety is one of the most important requirements
for any workplace. Slips and falls are among the most common
injuries at work. They account for about 86% of total injuries,
and 90% of these happen because the floor is wet

These injuries are particularly prevalent slips and falls the floor should be kept vary widely between countries. In the
in the food industry, where they occur clean and dry. In food and beverage EU, for instance, some regulations exist,
four times more often than the average production environments, this may not but there are no common requirements
in other industries. Injuries can create always be possible. Striking the optimum that companies have to follow. In coun-
significant impacts to all involved. The balance between safety and production tries such as the UK, USA, and Australia,
most significant is the suffering and realities is not always an easy task. there are, and these may be linked to a
possible disabling of the person injured. higher incidence of litigation.
The next is impact on the company — Often, for instance, there is a conflict
financial, loss of key staff, loss of produc- between cleaning and surface rough- The most widely used method of
tivity, and liability. ness of a floor. While the supervisor of measuring the slip resistance of a floor
the facility may be looking for a rough, worldwide is the Pendulum Tester, also
MINIMIZING TRIPS AND FALLS anti-slip floor for safety’s sake, the main- known as the Portable Skid Resistance
There are four main contributing factors tenance manager may prefer a smooth Tester, the British Pendulum (Picture 1),
that can cause a worker to slip and fall surface that is easy to clean instead. and the TRRL Pendulum. It is currently
down. These include: environment, The solution usually involves a trade-off a standard in 49 countries on five
organization, individual, and footwear between the two. continents.
(Table 1).
REGULATIONS AND MEASUREMENT The American ASTM E303-93 and UK
It goes without saying that to reduce Regulations regarding slip-resistance BS EN 13036-4-2011 slip-resistance

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22 Issue #2 | 2016
THE MOST WIDELY USED METHOD OF MEASURING
THE SLIP RESISTANCE OF A FLOOR WORLDWIDE
IS THE PENDULUM TESTER
standards are what define the Pendulum And other widely used test method is a Two other dynamic “in-situ” test methods
Tester as a measuring device. Australia variable-angle ramp test that is based use the Tribometer and SlipAlert testers.
uses it as well and its HB 197:1999 stan- on the DIN 50197 and DIN 51130 anti- Each provides a practical and fast
dard is known to provide the most slip standards. In this test, flooring method of defining the surface coeffi-
detailed information for wet Pendulum strips are mounted on a movable ramp, cient of friction. These methods can be
Tester values in different situations. and an operator wearing safety boots used on both wet and dry floors. SlipAlert
walks on them in one direction, and is also adopted by the British BS 8204-6:
The TRRL test method uses a dummy then back again in the other. The ramp is Synthetic Resin Flooring standard, and is
foot that swings down and makes then slightly inclined in stages until the used mainly in the UK as a more practical
glancing contact with the floor surface operator slips. The angle at which slip- method than the TRRL Pendulum.
being tested. The unit measures the page occurs is recorded as the “R value”
coefficient of friction (CoF) between the of the floor. Variable-angle ramp tests Indication of slip potential in water-
two surfaces (the floor and the bottom done in the food and beverage industry contaminated conditions can be obtained
of the foot) at the moment of impact. often include oil contaminants added by using a micro-roughness meter to
The test equipment is portable allowing to the floor strips to simulate real-life measure the peak-to-valley roughness of
“in situ” use while a facility is in full oper- conditions. These types of tests are well the floor surface. Results are expressed
ation. The test can be executed on wet or suited to heavily textured or profiled as a floor’s “RZ” value, which does not
dry floors, and slip-resistance results are surfaces. directly state slip-resistance but does
expressed as low, moderate or high. provide an indication of slip potential. The

TABLE 1. FACTORS CONTRIBUTING SLIPS

Causative factor Control measure
Environment Contamination of the floor Eliminate the contaminants
(spillages, debris, wet cleaning)
Slip resistance of the floor not maintained properly Remove debris and clean more thoroughly
­(incorrect or inadequate cleaning)
Slip resistance of the floor is too low Increase slip resistance or lay a more slip resistant floor
(inadequate floor roughness)
Steps and slopes — steps are too sudden and not well Ensure that steps and slopes are well marked and ­provide
marked; slopes are too steep adequate foot and hand hold and stability
Adverse conditions hiding floor conditions Remove hidden obstacles; provide adequate lighting
The nature of the task and movement on the floor (need to Encourage more care walking in slip areas
carry heavy loads, turn and move quickly, pull loads)
Organization Layout of work premises and general traffic flow Identify slip potential areas and encourage safer ­behavior
and vigilance
Safety culture Education and promote positive, proactive attitudes to
safety in general; measure and communicate safety prog-
ress on continual basis
Supervision Monitor risks and behavior and correct accordingly
Footwear Shoes and slip resistance must match Suitable shoes. Right kind of sole material and texture for
the floor surface
Individual Safety is everyone’s responsibility Provide adequate training; reward individuals who
­introduce better, safer ways of working

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Issue #2 | 2016 23
 determining slip-resistance in combina-
tion with the Pendulum Tester or other
dynamic method.

TABLE 2: NEEDED MICRO-ROUGHNESS

FOR CONTAMINATION
Minimum Contaminant
­roughness, µm
20 Clean water, coffee,
soft drinks
45 Milk, soap solution
60 Cooking stock
70 Olive oil
>70 Margarine

Picture 1: TRRL Pendelum Tester. CLEANING AND MAINTENANCE

Cleaning methods must always be
micro-roughness hand-held meter is easy Contamination adjusted to the environment and oper-
to use and is often employed to double Floors can be contaminated by a wide ations. Higher surface roughness, for
check Pendulum Tester data. A limitation variety of things, such as water, fats, oils, instance, requires more scrubbing and
of the unit, however, is it cannot be used food debris, and a combination of them. mechanical work, and a rough floor needs
for exceedingly rough floors. The greater the contaminant viscosity, the to be flushed with higher amounts of
greater the texture required to achieve the water than a smooth one. On the other
MANAGING THE RISK OF desired slip-resistance. Table  2 indicates hand, constant application of intense and
SLIP RESISTANCE the typical minimum values of peak-to- frequent mechanical cleaning may wear
When selecting the texture of the floor valley roughness levels, as measured by down the floor surface and result in lower
surface for required slip-resistance, the the micro-roughness meter, required slip resistance over time than what was
four most important issues to consider to give satisfactory slip-resistance for originally specified.
are degree of contamination, applied different contaminants.
cleaning regime, slopes, and the shoes or For this reason, some owners have intro-
boots that personnel are wearing. This is a good supplementary way of duced the “Sustainable Slip-Resistance”
approach for their production facilities.
In this case, long-term slip-resistance is
GRAPH 3: FACTORS INFLUENCING ON SLIP POTENTIAL checked by a test in which the coefficient
of friction is measured at the outset for
Floor a new floor surface and then again after
Cleaning
material numerous cleaning cycles.

The most effective cleaning method

normally requires the use of mechanical
Environment Contamination
floor cleaning machines in conjunction
with appropriate cleaning chemicals. An
Slip potential important part of managing slip resis-
Use Footwear tance is to ensure the cleaning regime
complies with the flooring manufactur-
er’s recommendations.

Behaviour

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24 Issue #2 | 2016
SELECTING FLOOR ROUGHNESS IS OFTEN
A TRADE OFF BETWEEN CLEANIBILITY
AND SLIP RESISTANCE
SLOPES AND SURFACE REGULARITY Flaws in surface regularity can cause trip Safety is everyone’s responsibility, from
Slopes are needed to move liquid across hazards, increased wear, problems with the very top of a company to people
the floor to a drain by gravity. Meanwhile, vehicle wheels, and difficulties installing working at all levels. Safety should be
slip-resistance requires surface rough- equipment. Surface regularity is gener- a fundamental part of every company’s
ness, which can impede the flow of liquid ally measured by a 2 m straightedge laid corporate culture. Workers who feel the
toward a drain. Steeper falls increase flat against the screed and measuring company cares about them care about
the gravitation effect but may create any deviation between the two with a the company.
problems underfoot. There are no stan- slip gauge or other device. According to
dards for falls, but food industry norms British Standards specifications, surface At Sika, we have the products and
suggest ratios between 1:100 and 1:80, regularity for screeds are classified as in services to help make your workplace
and as much as 1:50 in free draining the Table 3. safer and more productive. We can help
floors. Notwithstanding, a textured you choose the right flooring with the
surface may require a higher fall to allow FOOTWEAR right functionality, the right ease of
fluids to drain naturally. In industrial flooring situations where cleaning, and the right level of surface
floors are wet and contamination is roughness for all parts of your facility.
The degree of fall and the surface regu- unavoidable, workers should use foot- When you think floors, think Sika.
larity i.e., flatness of screeds, largely wear specially designed for those condi-
determine the tendency for water tions. Not all “safety” shoes are neces- REFERENCES
HSE information sheet:
and other contaminants to “pond” on sarily safe in all situations. The material Food Sheet No 6. 9/1998
the floor. Ponding can result in higher that a sole is made from and its texture
contaminant film thickness, which can will determine its slip-resistance against HSE: Assessing Slip Resistance. 5/2012
reduce slip-resistance. For synthetic resin a given floor surface. After matching up FerFa: Measuring and Managing the Level of
flooring, the BS8024-1 standard specifies variables, shoes and boots should be regu- Slip Resistance Provided by Resin Flooring.
the degree of regularity required to mini- larly inspected for wear, as should floors 4/2012
mize ponding. for any significant surface changes. Christopher G.J Baker: Handbook of
Food Factory Design. 2013

TABLE 3: SPECIFICATION FOR SURFACE REGULARITY

Class Maximum Permissible Application
Departure from a 2 m
Straight Edge – mm

SR1 3 mm High Standard: Special floors

SR2 5 mm Normal Standard: Normal use

in commercial and industrial
buildings

SR3 10 mm Utility Standard: Other floors

where surface regularity is
critical

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Issue #2 | 2016 25
 A GOOD CHOICE IS
AN INFORMED CHOICE
CLEANROOM MEASUREMENT TECHNOLOGY AS APPLIED TO FLOOR AND WALL SYSTEMS

There are a lot of things that different industries have learned from
one another over time. One example is the food and beverage i­ndustry
and what it’s learned from pharmaceuticals, ­particularly how those
­companies conduct their research and run their production operations.

Markus Keller, Gabriela Baum, and Udo contamination risks during manufac- a dangerous source of particulate emis-
Gommel of the Fraunhofer Institute turing processes, production environ- sions. Fraunhofer IPA developed a proto-
for Manufacturing Engineering and ments need to be carefully planned to type “Cleanroom-suitable tribiological
Automation IPA in Stuttgart, Germany ensure that no sources of contamination test bench IPA” to measure particulate
developed a white paper entitled will be present in the final product,” say emissions from material surfaces.
“Research on hygienic coating systems: the authors. “Due to the large exposed
particle emission, outgassing, chemical surface area in production settings, BIOLOGICAL RESISTANCE
resistance, biological resistance and coating materials that are used to make Biological resistance has to do with
cleanibility.” walls and floors need especially to be whether materials are inert to molds and
taken into consideration.” This relates bacteria, or if microorganisms are able
The paper is based on extensive research largely to the particles they emit, but to interact with them. For example, if
done by Fraunhofer IPA. The research also includes chemicals, outgassing and process water accumulates in the joint
reflects a pharmaceutical approach to other factors as well. of a poorly sealed flooring system, mold
measuring the various properties and spores if present could flourish because
environmental effects of floor and wall One of these factors is air quality as of the good local growing conditions
coating materials inside a food plant. The described in the EU-GMP Guideline Annex (humidity, temperature, nutrients) and
result is the creation of additional tools 1 for the manufacture of sterile pharma- become a major source of infection.
which owners and specifiers can use to ceutical products. In a typical produc-
make informed choices regarding the tion environment, for instance, particles How resistant are various materials to
best materials suited for their specific between 10 and 20 µm in size make up harboring mold and bacteria growth?
operational needs. As the paper’s title the majority of airborne microorganisms. Right now, the only measurement
implies, it’s far ranging in scope. It also Reducing them by 5 µm or more auto- method used is simple visual observa-
sets the pharmaceutical industry as matically reduces the count. tion made after a material allowed to
a benchmark for the food industry. incubate at a certain temperature for a
There’s a strong correlation between Wear and tear are other factors — certain time with results plotted on a
the two, one reason being they have to stresses caused by transport trolleys, chart for comparison against other mate-
combat the same enemies: particles and forklifts, and other equipment and the rials. Currently, there’s a push to replace
microorganisms. potential they have in releasing particles subjective visual assessment with more
from floor abrasion into the air. Further, reliable objective mechanical assessment
PARTICLE EMISSION if a material corrodes or becomes brittle instead.
The white paper begins with an overview and cracks as the result of an aggres-
of the importance of a hygienic manufac- sive cleaning agent, it not only loses its VOC OUTGASSING
turing environment. “In order to minimize material properties, but may also become In case of reactive systems (e.g., organic

@YourSurface
26 Issue #2 | 2016
resin floors versus tiles or ceramics), care with results recorded in comparison. measured, photographed and plotted for
must be taken to ensure that the outgas- The chemicals used in the test present comparison against other test samples.
sing of organic contaminants (VOCs) is a representative spectrum of chemicals
kept to a minimum in order to protect used in cleaning and disinfection agents. CONCLUSIONS
employees and if sensitive processes A comprehensive understanding of the
are concerned the products as well. The CLEANABILITY many aspects of cleanliness in hygienic
quantity of organic compounds released A clean floor makes for a healthy manufacturing is the key to selecting
into the air depends on surface area, working environment and safe, healthy suitable flooring systems for hygienic
outgassing time, age and temperature of food. Different floor and wall systems production in every industry including
the materials in question. have different cleanability characteris- food and beverage. Reliable and consis-
tics. Which one is best suited for your tent procedures for measuring particle
The process Fraunhofer IPA used to operation? A well-known and widely- emissions, biological resistance, VOC
determine outgassing of various floor and used method of finding out is called the outgassing, chemical resistance, and
wall coatings in this research involved Riboflavin Test. cleanability make it possible to compare
a number of sophisticated measuring materials objectively. Many of the test
instruments and a micro chamber heating It consists of preparing a contamination procedures in this research are either
device that hold the test material pieces solution made of 0.2 g riboflavin, 1000 already part of an ISO standard or in the
at 22° +/-1°C for one hour before gases ml ultra-pure water and 5 g hydroxyethyl process of becoming one.
were siphoned off for analysis. cellulose and spraying it onto the test
piece. Once it’s dry, it simulates a worst- As for the pharmaceutical industry, it’s
CHEMICAL RESISTANCE case contamination scenario including always been cleanroom-friendly and
Different materials react differently to the most stubborn soils possible. To recognized for having pioneered a scien-
the same chemicals and there are several clean it off, a cleanroom cloth is moist- tific approach to measuring the cleanli-
internationally recognized methods ened with ultra-pure water and wiped ness of a plant, its processes, and the
for assessing their resistance to them. over the surface using a linear wiping materials in a consistent and objective
Flooring materials, particularly in food simulator with standardized surface manner. It’s encouraging to see the
and beverage plants, should have the pressure and wiping speed. There are food industry catching up. This research
highest level of resistance. Case in point: machines set up to do this in a controlled program led by Fraunhofer IPA and
as a rule of thumb the under-surface and consistent manner. After wiping, supported by SIKA is an important step
of a flooring system should be perma- residual fluorescence from the solution is in this direction.
nently sealed and liquid-proof. If it isn’t,
liquid residues from a previous cleaning
or disinfection process can linger for long THE RESULT OF A CLEANABILITY TEST OF THREE
periods. If the flooring has poor chemical DIFFERENT SURFACE FINISHES
resistance it will likely start corroding as
Smooth surface Broadcasted ­surface Textured surface
a result.
Prior to cleaning

The procedure for assessing chemical

resistance is called ‘Immersion Test’.
The flooring samples measured are
placed in a receptacle filled with the
After cleaning
chemical in question. The receptacle is
then hermetically sealed. After being
exposed for periods of one, three, six
and 24 hours, the materials are exam-
ined under a microscope for blistering, Result Excellent None Excellent
discoloring, swelling, softening, reduced Source: Fraunhofer IPA.
scratch resistance, and other effects,

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Issue #2 | 2016 27
 PUTTING HYGIENE FIRST
Food hygiene, public health and ultimately the success of any food
manufacturing business is influenced by a number of important factors,
one of which is drainage. Here, Mr Vaclav Kralicek, ACO Group Segment
Manager Food and Beverage, gives us an overview of some of the key
areas to consider when it comes to specification.

Thanks to recent research and improve- performance, you can’t afford to consider shrinkage of the floor substrate all need
ments in best practice guidance issued drainage in isolation. You need to take to be considered. This approach helps
by various bodies, the food and beverage three core areas into consideration: to minimise the risk of cracks forming
industry increasingly recognises that Drainage, flooring and cleaning. To quote where the flooring and the drainage
poor hygiene can be caused as a direct the European Hygienic Engineering and connect, and removes the associated risk
result of bacteria that’s present in a Design Group (EHEDG), a leading source of bacterial harbourage.
processing facility’s drainage. As a result, of independent best practice advice,
it’s now widely accepted that hygienic “Drainage should be considered holisti- The flooring itself also needs to be fit for
drainage is critical to any food manu- cally from a site perspective as the site purpose with regards to slip resistant,
facturing or processing facility whether and each subsequent level of analysis has durability and its load-bearing capabili-
you’re an international brewer or your potential impact on hygienic operation.” ties, and both the drainage and flooring
business manufactures ready meals for need to work practically with the cleaning
a major supermarket. It’s essential that the drainage, flooring protocol for a facility.
and cleaning regimes are compatible. The
So what specification factors are critical drainage design needs to connect prop- Failure to consider the compatibility as
to the optimisation of hygiene? erly with the surrounding flooring, an well as the suitability of flooring and
One of the key things to understand is appropriate sealant needs to be used and drainage designs can result in long term
that if you want to ensure good hygienic the mechanical loads, thermal loads and durability issues, higher than necessary

@YourSurface
28 Issue #2 | 2016
ACO HYGIENIC DRAINAGE
1 Edge infill
Design ensures stable and du-
rable transmission between the
gully and surrounding floor.
3
2 E ffective slope
Build in slope +1% eliminates
standing water and increases
2 cleaning effectiveness.

3 Corners ≥ 3 mm
1 Internal radii measure ≥3 mm
which increases cleaning effec-
tiveness.

4 Dry sump
Completely drainable design
4 which eliminates standing water.

cleaning costs, bacterial contamination the cleaning methodology and chemicals pickling or pickle paste run the risk of
and the ineffective collection of water that will used during the cleaning process failing to meet longer term durability
and other liquids which then present a before deciding which grade of steel to requirements.
risk to both hygiene and via the creation use. Refer to EHEDG Doc 8, section 6 for
of a slip hazard, health and safety. more information. 4. PRODUCT DESIGN ­CONSIDERATIONS
This affects both functionality and
When it comes to the drainage design 2. WELDING PROCESS ‘cleanability’. At the most basic level, ask
itself, it needs to be fit for the purpose. The manufacturing process with regard yourself these questions: Is your design
Key questions to ask include: What to welds and welding should follow fully drainable, does your drainage have
type of drainage – line or point - is most the best practice recommendations rounded corners with minimum radii of
appropriate; what falls are required in of EHEDG Doc 9 and Doc 13, Section 7. 3 mm and can your drainage be cleaned
the floor; does the drainage system Amongst other things, Doc 13 advises without power-washing?
layout work in the context of the equip- “welds must be continuous, round,
ment you plan to use; what hydraulic smooth, ground and/or polished”, over- If your drainage isn’t fully drainable its
capacity will you need, and what load lapping joints must not be used (if you hygienic performance will be compro-
and therefore what grating design will weld a lap join you create a void and that mised. Drainage channels need to have
be required? The choice of drainage will void will harbour bacteria) and welds completely drainable dry sumps with
also depend on whether it’s required should not be made in corners (if the engineered positive drainage features
for use in a high, medium or low risk drainage you specify is welded on a flat which prevent the build-up of stagnant
area. A number of even more detailed area, the manufacturer can ensure the water, odours, microbial growth and
specification criteria then come into weld is smooth and smooth contours potential chemical hazards.
consideration. eliminate crevices that can harbour
bacteria). Sharp corners are harder to clean, partic-
1. CHOOSING THE RIGHT STEEL ularly if they’re situated at a right angle
Where hygiene is concerned stainless 3. PICKLE PASSIVATION or bend which means there’s a very real
steel to EN 10088 with a roughness If it’s not fully pickle passivated (FPP), risk that the corner won’t get cleaned
factor of 0.3 to 0.8 micro-metres should stainless steel will suffer from corrosion effectively. To meet EHEDG best practice
be used. An engineer or hygienic tech- and pitting which will lead to a risk that guidelines, drainage should have rounded
nologist also needs to consider oper- it can’t be properly cleaned. It’s essential component features and corners with
ating conditions such as acidity and that the drainage system is FPP (EHEDG minimum radii of 3mm.
temperature, and to fully understand Doc 18). Processors which use localised

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Issue #2 | 2016 29
 And in spite of what some companies the drainage supplier with a waterproof Finally and importantly, is the choice
will tell you, one of the worst things you material which can resist the vertical and of drainage design and flooring future
can do is power-wash drainage. Power- horizontal stresses placed upon it and so proofed? Food trends change continu-
washing creates a high velocity spray eliminate areas for bacterial growth. ously but, construction and refurbish-
that spreads the bacteria living in the ment of food manufacturing facilities is
drainage around the facility. Drainage 6. OPERATIONAL CONSIDERATIONS a long term investment and areas such as
should be designed in a way that ensures Good health and safety plus cost floors and drainage are costly and disrup-
power-washing is not required. management are key to any successful tive to change. By considering long-term
business. To optimise the safety of requirements at the start instead of the
5. INTEGRATION OF DRAINAGE employees, some very basic require- end of the design process, food factory
INTO THE FLOOR ments include the specification of slip operators can save themselves a great
As stated earlier in this feature, the resistant products and easy handling deal of money and inconvenience in the
quality of drainage/floor connection is grates to avoid injuries and cuts. longer term.
as important as drainage and flooring
quality itself. Improper drainage/floor With regards to cost, ask yourself how In conclusion, drainage and flooring have
connection can compromise hygiene and cost efficient will the drainage system a significant impact on the successful
lead to downtimes with costs attached be in the longer term? Is it easy to clean, operation of any food or beverage manu-
to it. Best practice advice given in EHEDG reducing labor costs and downtime, is facturing facility. There are many other
document no. 44 – Hygienic design of it durable so it requires the minimum standards and guidelines you can refer to
food factories – states that drainage amount of maintenance and how easy but even if you only meet these criteria,
channels and gulies must be designed is it to work with on a day-to-day basis? you will have taken some significant
with usage of U-shaped visible edge Asking these questions at the design steps to putting hygiene first.
profile of not less than 1.5 mm thick- stage saves valuable time and money.
ness. Any edge profile should be filled by

@YourSurface
30 Issue #2 | 2016
CHOOSING SEAMLESS WALL
COATINGS FOR YOUR PLANT
Hygienic wall finishes are an important aspect of every food plant. Walls inside
a production facility cannot fail — surfaces shall not flake, the walls cannot
emit particles or gasses that could affect the quality and safety of the food
being processed, they have to have easy and effective cleaning capabilities
at any temperature, they must be resistant to the cleaning and disinfection
regime in place, they need to expand and contract without cracking, they
should provide a smooth surface, have a good impact resistance and, last but
not least, be affordable.
And that’s done by coating absor- normal production, walls present many The only part of a wall that isn’t natu-
bent surfaces like blockwork, concrete, more options in material choice and rally protected is the area closest to the
and renders with the right specialized design than floors, which have to put up floor. It can suffer damage from forklifts,
finishes. with forklifts and other traffic, heavy pallets, falling tools, and other things.
machine weight, chemicals, intense heat, For this reason, in addition to choosing
Considering their construction and the and other stresses. the right coating, base details have to
fact they are largely out of the way of be taken into account and safeguards

@YourSurface
Issue #2 | 2016 31
 put into place, such as barriers made of Meanwhile, less critical areas often use ́́ Harmful process conditions such as
material that’s strong enough to absorb unreinforced systems, namely paint steam vapor
any impacts. coatings. These tend to be rather thin ́́ Lack of resistance to hygienic
(less than 500 microns) and lose their processes such as chemicals, disin-
UNREINFORCED, REINFORCED stability if they become detached from fectant used and low pressure steam
Coatings are applied in liquid form and the substrate. cleaning
there are two main types: unreinforced ́́ Change in the original use of the
paint coatings, and reinforced resin These systems are normally used in building
coatings. areas such as corridors, warehouses, High performance coating materials
staff rooms, and other areas. If used in perform best in food processing areas
Each has its own special characteristics open food processing rooms, they have when used with a reinforcement mat.
and both are used in new installations a potential for flaking off and contami- The glass fiber laminate bonds the resin
as well as in the renovation of existing nating the food being produced. and reinforces the coating. This elimi-
wall surfaces, such as glazed tile, plaster, nates the potential for flaking and forms
brick, concrete and others. Some of the reasons why coating a self-supporting structural layer.
systems fail, no matter if they are unre-
Among the most common coatings inforced or reinforced, include: Reinforced resin laminates are an excel-
found in typical food processing facilities ́́ Deterioration of the substrate lent choice for refurbishing existing wall
are reinforced two-component epoxy ́́ Water vapor permeation through the finishes such as old tile, or for providing
and polyurethane resin-based products. thin film a new hygienic finish to unsuitable wall,

@YourSurface
32 Issue #2 | 2016
WITH RESIN COATING SYSTEMS THE JUNCTIONS
CAN BE MADE TOTALLY SEAMLESS
column or ceiling constructions such as the Sikagard® Wallcoat AS-13 or AS-53, The wide range of Sikagard® Hygienic
concrete, brick, plaster, and rendered which can tolerate dampness. Coating systems are ideally suited for all
finishes. areas of a food and beverage facility —
Often the surface profile of the existing from the office to warehouse, and from
SEAMLESS wall will show through the wall coating. process area, to packaging rooms and to
Reinforced resin laminate systems are This will not affect hygienic performance, clean rooms. They are resistant to mois-
seamless. In the application process, but if it’s not desired the solution is to ture and are elastomeric, which means
laminate sheets are merged or staggered render the wall to achieve a flat surface. they can adjust to thermal and structural
with adjacent sheets “wet on wet.” The Most coating systems for food environ- movement without flaking or cracking
adhesion between the laminate and the ments are based on acrylic, water-based and bridge cracks up to 1 mm width,
cured layers is excellent, and the joints epoxy and polyurethane resins, which depending on the chosen reinforcement.
in the finishing layers are also staggered produce little odor or taint during the Because the systems are liquid applied,
providing not only a seamless appear- curing process. Good colors to choose are they are easy to repair simply with
ance, but more importantly seamless lighter shades for functional and hygienic more liquid if needed, which increases
performance. reasons. system life expectancy and minimizes
maintenance.
The final thickness of the system WHY RESIN?
depends on the number of layers applied. The big advantage in using resin lami- Sika coating have been fully tested in
Normally for wall finishes, the layer thick- nate coating systems for walls and ceil- accordance with many European stan-
ness is appr. 1 mm. However, laminate ings is that junctions are totally sealed dards, including EN13501 (behavior to
mats can be found in any thickness. and provide no easy environment for fire), ISO 846 (biological resistance), EN
bacteria and mold to grow. Sikafloor® 18033 (wet scrub resistance and opacity)
When applying the laminate, the and Sikagard® solutions provide a and ISO 22196 (Antimicrobial activity).
substrate must be clean and solid. simple and highly effective method for
Whether the substrate needs to be achieving surfaces that are smooth and To ensure low emitting properties
primed or not depends on its condition. In easy to clean, hard wearing, and free Sikagard® Hygienic Wall coatings are
case the moisture content is high, which from joints and other features that can also equipped with A+ certificate, related
often occurs in refurbishment projects, create a hiding place for dirt and bacteria. to French requirements for indoor air
it’s best to choose a system, such as quality.

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Issue #2 | 2016 33
SELECTION GUIDE –
A COMPLETE SOLUTION
FOR BEVERAGE FACILITY
SURFACE FINISHES
The manufacture of beverages includes Soft Drinks, Water, Fruit
Juices, Brewed products, Milk based products, Health foods and
others. This guide is confined to water based products and juices;
all liquids as presented for sale.
Unit processes in such plants are not complex and, depending OFFICE AND UTILITY AREAS
upon product, include extraction, blending and packing; some
refrigerated storage may be included. Non-chilled products In addition to process area, commonly production facilities have
are usually subjected to UHT 1, heat, processing. As such prod- number of other utility and office rooms including:
ucts are for human consumption, manufacturers have special ́́ Laboratories
concerns over hygiene and consistent product quality; there- ́́ Social rooms and lavatories
fore most unit operations are fully enclosed using pipelines and ́́ Offices and meeting rooms
pumping to transport in a plant, follow strict hygiene regimes, ́́ Canteen
involve many stages of quality control, employ the highest ́́ Kitchen
standards of cleaning and maintenance and high speed packing
including aseptic systems.
BASIC BEVERAGE INDUSTRY
PROCESS AREAS FLOOR REQUIREMENTS
RAW MATERIALS
UNIT PROCESSES The list of component materials in beverages may be large
́́ Extraction - in case of fruit juices and concentrates; usually including:
done in cold. Chillers for storage. ́́ Water
́́ Sugar solutions manufacture - concentrates made by ́́ Fruit juice extracts
dissolving raw sugar in water at elevated temperatures. ́́ Fruit juice concentrates
́́ Liquids blending – sugar solutions, water, concentrates, ́́ Sugar and sugar solutions
flavorings, colorants, preservatives, additives etc. often at ́́ Proprietary concentrates
elevated temperatures. ́́ Carbon dioxide
́́ Sterilization – maybe in-line or in steam heated autoclaves ́́ Fruit acids – e.g. citric, acetic, maleic, malic, ascorbic
if product already canned. Also UHT(1 process) ́́ Preservatives – e.g. sodium benzoate, benzoic acid sodium
́́ Packaging – in variety of containers including cans, PET sulphite
bottles, glass bottles, crates, and pallets. ́́ Mineral salts – e.g. chlorides, nitrates, bicarbonates,
́́ Sealing and labeling sulphates, phosphates
́́ Chilling ́́ Inorganic acids – phosphoric
́́ Flavorings – natural and synthetic, often oily in nature
OTHER PROCESSES ́́ Colorants – natural and synthetic, caramels
́́ Storage and preparation of cleaning material specially CIP ́́ Dispersants – surfactants, emulsifiers, sometimes solvents
systems ́́ Vitamins
́́ Bottle washing – caustic washers at high temperatures
often with steam – such facilities may be in-line with CLEANING CHEMICALS
automatic washers/rinsing equipment/driers with bottles ́́ Inorganic acids – nitric, phosphoric, hydrochloric, sulphuric
passing direct to filling lines. ́́ Organic acids – citric, oxalic
́́ Large stainless steel component storage facilities with ́́ Alkalis – caustic soda, caustic potash, ammonium, carbon-
associated pumping plant. ates, bicarbonates, hydroxides
́́ Storage of raw materials ́́ Surfactants – nonionics, anionics, cationics, amphoterics
́́ Washing of incoming raw materials – fruit – with weak ́́ Sequestering agents – EDTA, metasilicates, organic
alkaline solutions ­phosphates
́́ Peeling, if required. ́́ Sterilants – hypochlorites, iodine complexes, cationics,
́́ Waste storage and treatment peroxides, amine complexes
́́ Water treatment and purification ́́ Proprietary acid and alkaline products
́́ Warehousing and dispatch ́́ Proprietary blended sterilants, bactericides and bacteristats
́́ Quality control laboratories + detergents

TRAFFIC
Mainly foot and fork lift trucking around 5 tons gross weight
especially in packing and dispatch areas and where containers
are stored and handled. CIP chemicals may be delivered in bulk
but this operation is usually external to plant.

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Issue #2 | 2016 35
 IN A BEVERAGE PLANT THE FLOORS IN
MOST AREAS ARE CONTINOUSLY WET.
THIS CAUSES ­SAFETY AND HYGIENE
­CONSIDERATIONS
SPILLS Surfaces must:
As processing of Beverages is a liquids operation, the potential ́́ Resist spills of raw materials and chemicals
for spillages throughout a facility is high. Facility flooring may ́́ Be capable of withstanding raw materials and chemicals at
often be continuously wet; so floors are laid to falls to drains, temperatures up to 100ºC
usually stainless steel. Further, wet floors create a potential ́́ Not support microbiological growths and be sterilized with
for slipperiness so that non-slip finishes are needed on safety steam, if necessary
grounds. ́́ Be non-slip and safe
́́ Be laid to falls to drains
Spillages are usually water based but may contain any of the ́́ Be capable of withstanding thermal shock
raw materials and chemical cleaning and chemical processing ́́ Be non-staining, non-dusting, non-toxic, biologically inert,
materials; rarely at high strength except for sugar solutions odor free
and cleaning chemicals that may be at elevated temperatures ́́ Withstand mechanical wear and tear; resist fork lift truck-
rendering them more corrosive. Being water based, there is ing, abrasion and impact
potential for evaporation of the water solvent thus becoming ́́ Be easy to clean and maintain
more concentrated and corrosive. ́́ Be integrated with minimum of joins and seams;
coatings enveloping all surfaces
Spills of organic matter such as fruit pulps, sugars etc are a ́́ Have aesthetics required for food industry standards.
potential for microbiological action especially in the warm and ́́ Meet any relevant industry regulations and standards
wet environment.
Any and all seals at drains, tops of coves, expansion/isolation/
PROBLEM AREAS construction joints, footings for vibrating equipment etc. shall
As floors are almost continuously wet in most areas, there are be formed and filled with a sealant Sikaflex® Pro3.
Safety and Hygiene considerations.
The whole of coated surfaces, horizontal and vertical shall be
The use of hot concentrated sugar solutions, organic acids and keyed together to provide a continuous integrated enveloping
high temperatures, including steam, of cleaning systems both surface over the entire plant substrate.
of plant and containers, creates a very aggressive corrosive
environment especially when there are spillages. The moist All recommendations are to be executed on correctly prepared
and warm environment is conducive to microbiological growths, concrete substrates in accordance with Sika published instruc-
especially mould on floor, wall and ceiling surfaces; any surfaces tions by an approved, trained and supervised Specialist
that are porous. Contractor appointed by Sika. Preparation shall be executed in
accordance with Sika instructions and recommendations.
There is a need for run-off to drains of all liquid spills and ease
of wash-down and removal of cleaning material; floors must
be laid to falls and an integrated floor to drain seal that can
1
 HT (Ultra-high Temperature Processing or Ultra-heat Treatment) steri-
U
lizes food by heating it above +137°C – the temperature required to kill
take differential thermal movement. In addition, Food Industry spores in milk – for 1 to 2 seconds. UHT is most commonly used in milk
Standard coving, plinths for plant etc. must be installed and production, but the process is also used for fruit juices, cream, soy milk,
have same performance characteristics as the floor. yogurt, wine, soups, honey and stews.

https://en.wikipedia.org/wiki/Ultra-high-temperature_processing
With thermal shock a potential and cycling of plant temper-
atures, slab movement is probable; floors must incorporate
movement provisions. Also isolation of vibrating plant to slab
and floor structure is important in order to prevent the failure
through cracking and delamination.

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36 Issue #2 | 2016
 SIKA
FLOORING
AND
COATING
SOLUTIONS

@YourSurface
38 Issue #2 | 2016
 Sika flooring and coating solutions are
designed according to these types of
operations in general. However, the right
solutions to be specified in your projects
should always come from the personal
advices by a Sika flooring expert, because
the floor plans and requirements vary
from project to project.

Storage and Logistics Areas Wet Production and Processing Areas

Dry Production and Processing Areas Laboratory and Social Rooms Areas
Extreme Exposure Areas in Office Areas
Production and Processing

@YourSurface
Issue #2 | 2016 39
 SYSTEM SELECTION FOR BEVERAGE
FACILITY SURFACE FINISHES
Main Functional Zone Floor Solutions
­Process
Sikafloor® Sikafloor® PurCem® Sikafloor®
HardTop MultiDur
Sikafloor®-1 HM-20 HB-21 HB-21 Gloss HS-21 HS-21 Gloss HS-26 Gloss EB-24
MetalTop
Sikafloor®-2
SynTop

Unit ­Process Fruit Extraction1

Sugar/Syrup Plant1
Blending/Formulation Plant2
Sterilization/Autoclaves/UHT3
Packaging/Capping4
Labelling
Support Delivery Areas/Empty Bottle Reception5
­Processes
Raw Material Storage
Washing Incoming Materials6
Peeling6
Waste Storage6
Water Purification7
Chemical Storage
Raw Material Storage
Bottle Washing/Bottling1
Warehouse/Dispatch
Quality Control
Offices and Laboratories
­Utilities
Offices/Meeting Rooms
Reception
Social Rooms/Lavatories
Kitchen
Cafeteria

* Note: T hese are guide recommendations, always consult a local Sika 1

Thickness 9 mm
expert for specific project advise and specification. Local site con- 2
Thickness 6 mm
dotions and regulations may require a tailor made specification. 3
Thickness 12 mm recommended at access to autoclaves, 9 mm other areas
4
Thickness 4 mm. In wet areas HB-21 Gloss, in dry areas HS-21 Gloss

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40 Issue #2 | 2016
 Wall Solutions Ceiling Solutions
Sikafloor® Sikafloor® DecoDur Sika ComfortFloor® Sikagard® WallCoat Sikagard® WallCoat
Pronto
ES-24 ES-39 RB-24 EM-21 ES-21 PS-23 PS-27 PS-63 WS-11 AS-12 EL-13 AS-13 WS-11
Compact Granit PS-24 PS-64 ­Hygienic PL-15 Hygienic
PS-65 PS-11
PS-66

5
Sikafloor®-1 MetalTop Ideally suited Suitable
6
Thickness 4 – 6 mm
7
Thickness 4 mm. In wet areas anti-slip, in dry areas smooth system

@YourSurface
Issue #2 | 2016 41
 POWERFUL TRENDS ARE
DRIVING FLOOR AND WALL
EVOLUTION IN F&B
Stellar, fully integrated firm focused on design, engineering,
construction and mechanical services worldwide is ranked as one
of the top food processing design-build firms in the world. Based
in Jacksonville, Florida, its expertise in the F&B industry extends
over multiple market segments, including everything from
seafood and poultry to beverage, and bakery and ready-to-eat.
Manny Valdivieso, Architect AIA at Stellar, says demands on
floor and wall suppliers continue to increase, particularly as
economical and regulatory issues continue to tighten.

“We’ve found clients’ biggest concerns and recommends a system best-suited chemicals, temperature fluctuations
surrounding floor and wall surfaces to for the plant’s specific needs.” and mechanical shock from equipment
be financial, both with installation costs used on the surface,” notes Valdivieso.
and life-cycle costs,” says Valdivieso. DESIGN “Owners often assume their systems
“Owners want floor and wall surfaces Stellar employs the latest in Building will last a long time, so they do not
that are both affordable and specifically Information Modeling (BIM) to facili- discuss them in the preliminary design
suited to their food plant’s conditions. tate more educated decision-making phase. Instead, they discuss systems
Warranty options are also an important throughout the life of F&B projects. This with maintenance personnel after the
area of consideration.” technology allows owners to visualize a systems have already been specified and
facility in 3D before it’s built, and let’s designers are in the bidding stages.”
Floor and wall systems are a large part of then see the impact of any changes made
the facility investment material selection to materials and finishes. “It’s important He adds that the greatest potential for
process. The system must be durable and for floor suppliers to have BIM objects improvement from suppliers lies in dura-
equipped to withstand heavy washdown available to both facilitate and stream- bility and warranty options. If the right
practices while protecting the original line this process,” notes Valdivieso. information about project’s needs and
concrete surfaces, such as slabs and expectations is provided to the floor or
walls. Combining proven food expertise with wall suppliers by the owner and designers
BIM technology helps to ensure facilities up front, it could help them come up with
Valdivieso says when writing specifica- are sanitary and food-safe, effectively a more attractive system warranty.
tions and selecting floor and wall coat- optimize the space needed for produc-
ings, Stellar always discusses the owner’s tion lines, and accommodate the possible REGULATION TRENDS
requirements, washdown practices, and future need to move large equipment for Currently, there are a slew of compliance
chemicals. The firm also obtains the periodic maintenance or upgrades. considerations for the F&B industry,
owner’s MSDS sheets and provides the including product certification stan-
information to the supplier for review. Another key area of consideration is cost dards (SQF code), government policies
“We appreciate when the supplier of ownership. “The main criteria should (USDA, FDA’s Food Safety Modernization
reviews the provided documentation be how well the system will withstand Act), management systems (HACCP)

@YourSurface
42 Issue #2 | 2016
 Source: Stellar.
and agencies (OSHA). Stellar antici- be able to communicate in whatever are expert in processing design-build
pates the biggest trend in the future of country they’re working in. “The ability and with experienced suppliers such as
construction to be an increase in these to attend design meetings is also a huge Sika will help them make the right choice
requirements. advantage with suppliers,” Valdivieso in meeting their specific requirements
says. “In addition to being highly successfully.
He points out that as governing authori- trained, suppliers should also be able to
ties continue to increase sanitation easily articulate material and warranty “As a major design-build firm, we’ve
expectations, more hygienic and seam- options.” worked with Sika in a variety of markets
less floor and wall materials are taking around the world, and we appreciate their
command. “These are long lasting mate- These are some of the things on the top notch service, and impressive knowl-
rials that can withstand the impact of “wish list” owners have regarding their edge of floor, wall, and roof systems.
chemical abuse, thermal shock, and floor and wall suppliers. There are others. Working with Sika has been a favorable
temperature changes. Materials should He says working with companies that experience every time.”
also address vapor transmission from
substrate,” he notes.

That said, owners generally do not

request certificates, but they want their
systems to meet food industry standards
nonetheless. “Installers themselves hold
certifications illustrating they have
received proper training and are equipped
to install the systems properly.”

Communication is another important

Source: Stellar.

factor in meeting construction schedule

deadlines. Ideally, representatives should

@YourSurface
Issue #2 | 2016 43
 Sydney Fish market before renovation.

FLOOR RENOVATION IN AN
­OPERATING FACILITY – IT’S ABOUT
SPEED AND PRODUCT SAFETY
Renovating a food or beverage plant is complex work that has its own
unique challenges compared to building a greenfield facility. This a­ pplies
equally to ceilings, walls, doors, utilities, lighting, floors, and all other
major features.

One of the main issues during a reno- job are chosen and installed properly. In from odors, VOCs, and other emissions,
vation project is time, more specifi- the end, refurbished floors and all other especially during the application process.
cally downtime and how to keep it to a features should have the same level of At particular risk are the more sensitive
minimum, which means minimizing inter- hygienic and functional performance as products – wet or moist as opposed to
ruptions to production in other parts of those found in a greenfield plant. dry – such as dairy and meat.
the plant that aren’t being worked on.
In addition, the work going on should be Two things that affect the time needed Below are case studies of two companies,
clean, odorless, and isolated by barriers as to install a new floor are application and a fish market in Sydney, Australia, and a
needed to make sure food remains clean curing. Time can be saved with both by dairy in Günsburg, Germany. Both used
and uncontaminated, and employees choosing the right materials from the Sika flooring and contracting partners
remain safe at all times start, for instance ones that can handle who were certified to install them.
high amounts of humidity in the cement
All this requires good planning and seam- substrate if that happens to be the case,
less cooperation between the project which it often is. As for curing, choosing
parties. Leading the charge should be materials that do this faster than others
an experienced main contractor who can can also save time. A third factor to be
make sure the right materials for the mindful of is potential product tainting

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44 Issue #2 | 2016
Operations continued during flooring works.

FLOOR UPGRADE IN A FISH MARKET — ODORLESS WITH SHORT DOWNTIME

The Sydney Fish Market, situated on against taint, and that could stand the depth up to 50 mm using hydroblasting,
the edge of Blackwattle Bay, has been test of time for at least 20 years. which kept dust and airborne particles
an Australian institution since 1945. The to a minimum and provided a solid
market is the largest of its type in world The search ended when Danlaid substrate on which to re-build. Workers
with 50 tons of seafood being auctioned Contracting Sydney along with Sika then re-graded the base to create posi-
on the trading floor each day. Australia proposed a Sikafloor® PurCem® tive falls for water displacement, and
HB-21 flooring system to the client. applied an epoxy sub-fill mortar and the
The original floor of the market had to Sikafloor® PurCem HB-21 is a low VOC, Sikafloor®  PurCem® HB-21 finish layer
handle a lot of stress. It was constantly water-based polyurethane hybrid screed on top.
wet, and had to endure a constant that is certified for food industry use. It
stream of forklift trucks carrying or drag- is resistant to significant heat variations The floor ended up being part of a larger
ging heavy containers laden with seafood and chemicals, easy to clean and main- overall facility upgrade. It was business
from one end of the market to the other. tain, and well-suited to both dry and wet as usual throughout construction, and all
Add to this an incredible amount of foot areas. aspects met projected budget and time-
traffic, day in and day out. line schedules resulting in a well-satis-
Danlaid demolished the old floor to a fied client.
After many years or of applying a variety
of temporary fixes with varying results,
the owner of the Sydney Fish Market
decided it was time to upgrade to a food-
grade floor replacement.

This meant the old floor had to be

completely demolished, and the new
one prepared, re-graded and then laid
in stages, all while the market was still
open for business. This required careful
planning between all parties.

To prevent customers from being annoyed

and food from being tainted during the
process, the search was on for a floor that
produced little or no odor, even during
installation, that protected the food In Sydney Fish market 50 tons seafood is being auctioned every day.

@YourSurface
Issue #2 | 2016 45
 WHEN TIME IS MONEY, AND YOU ONLY HAVE A WEEKEND TO RENOVATE

Zott SE & Co. KG is a major European Zott’s goal was to replace the tiles with along with a bonding layer to level out
dairy based in Mertingen, Germany, a state-of-the-art seamless resin-based any uneven concrete and provide a solid
where the company’s main plant is situ- floor surface that was highly durable, base for the flooring surface. The surface
ated. There, it produces a variety of chemical resistant, easy to clean, and chosen was the seamless Sikafloor®
yogurts, desserts and “Zottarella,” the slip-resistant. An additional requirement PurCem® HM-20, a flooring system that
brand name of the company’s mozza- was timing – the whole job needed to be is proven to be highly resistant to chemi-
rella cheese. In 2012, it along with Zott’s done over a two-and-a-half day weekend. cals and thermal shock, and that is able
“Bayernthaler” became the first cheese The assignment went to Dynapox GmbH, to go into use a mere 24 hours after
products in Germany permitted to use a company based in Legefeld, Germany being allowed to set.
the “GM-free” label. that specializes in resin floor application,
especially for the food and beverage The result? Zott got a new state-of-
Bayernthaler, a hard cheese, is produced industry. the-art seamless resin floor for its plant
at a Zott plant in Günzburg, where all in Günzburg, saved a lot of money by
was not well with the tile floor. The tiles, Dynapox started on a Friday afternoon installing it over a weekend, and resumed
which were held down by an epoxy-based by removing the old tiles and the mortar full operations again the following
adhesive, had begun to show a lot of bedding. Next, workers applied Sikafloor® Monday morning.
wear and damage. HardTop-80 cementitious flooring screed

Zott Dairy in Günzburg.

@YourSurface
46 Issue #2 | 2016
SCHEDULE AT A GLANCE

FRIDAY AFTERNOON: Mechanical removal of old tiles and epoxy FRIDAY EVENING: Application of the bonding layer and the
adhesive. Substrate preparation and cleaning. cementitious fast curing Sikafloor® HardTop-80 flooring screed.

SATURDAY MORNING: Substrate preparation after curing of SATURDAY AFTERNOON: Application of the ­
the screed. Sikafloor® PurCem® HM-20 hybrid polyurethane flooring.

SUNDAY AFTERNOON: Floor back in use. MONDAY MORNING: Plant resumes full operations.

@YourSurface
Issue #2 | 2016 47
 SIKA@WORK IN FOOD
AND ­BEVERAGE
­INDUSTRY
A selection of international clients and their production facilities
where Sika solutions have been applied:
́́ Marbo Pepsico, Snack production, ́́ Cadbury, Chocolate, Port Elizabeth,
Backi Malic, Serbia South-Africa
́́ Valio, Dairy production, Riihimäki, ́́ Mills DA, Dairy products,
Finland ­Fredrikshamn, Norway
́́ Coca-Cola HBC, Bottling plant, ́́ Frigosorno, Meat processing,
­Dietlikon, Switzerland Osorno, Chile
́́ Ferrero, Chocolate production, ́́ Sölen Cikolata, Chocolate,
­Guanajuato, Mexico Gaziantep, Turkey
́́ Nestle, Coffee factory, Montes ́́ Orogel, Vegetable processing,
­Claros-Minas Gerais, Brazil Cesena, Italy
́́ Zott Dairy, Gunzburg, Germany ́́ Carrefour, Food handling and storage,
́́ Lactalis, Dairy production, France Spain
́́ SuKarne, Meat processing,Torreon, ́́ Lindner Hotel Gallery Central,
Mexico Kitchen, Bratislava, Slovakia
́́ Dafgards Bakery, Källby, Sweden ́́ Sydney Fish Market, Fish trade,
́́ Floridis S.A. Meat processing, Athens, Sydney, Australia
Greece ́́ SAB Miller, Brewery, Guayaquil,
́́ Vinicole de Rivesaltes Bourdoil, Ecuador
Winery, France ́́ Molinos Rio de la Plata, Frozen food ,
́́ Carlsberg, Brewery, Dali, China Pilar, Argentina
́́ Asahi Indofood, Beverages, Cicurug, ́́ Micarna SA, Meat processing,
Indonesia ­Courtepin, Switzerland

ISTANBUL METROPOLITAN RAIMBEK VOSTOK AGRO DRAKE

MUNICIPALITY, ISTANBUL, TURKEY UST-KAMENOGORSK, KAZACHSTAN ADELAIDE, AUSTRALIA

Sika solution: Sika solution: Sika solution:

Sikafloor® PurCem® for flooring in fish Sikafloor® PurCem® Gloss for flooring in Sikafloor® PurCem® for flooring in
storage and freezer floor a new dairy plant a meat processing plant

@YourSurface
48 Issue #2 | 2016
PILGER BAKERY MALTEUROP SCHENK ES TARSA KFT
BREITENBERG, GERMANY VITRY-LE VINCENT, FRANCE SZIGETVAR, HUNGARY

Sika solution: Sika solution: Sika solution:

New bakery using Sikafloor® PurCem® Sikafloor® PurCem® for flooring and Sikagard® Hygienic Wall Coating in a
flooring Sikagard® Hygienic Wall Coating for food plant refurbishment
vertical surfaces in a plant refurbishment

@YourSurface
Issue #2 | 2016 49
 HYGIENICALLY SEALED DETAILS
Joints and junctions are the weakest part of a flooring system in industrial
environments. They are exposed to similar stresses as the floor itself, but
also need to accomodate possible movements in the structure or b ­ etween
building components. Normally joint materials are elastic and also show lower
resistance against mechanical and chemical stresses than the flooring ma-
terial. These joints are most apparent between different components (e.g.
drains, gullies), between floors and walls and around columns and entrances.
­Damaged, leaking and worn out joints allow dirt and bacteria to harbor.
In general, joints and details make daily Unique advantages with jointless However, there is no way to prevent
cleaning and maintenance more difficult hygienic junctions provided by Sika prod- all of the joints in floors. The concrete
and time consuming when compared to ucts include the following key features: substrate is subject to shrinkage during
seamless flooring. Building owners and anti-microbial, non-porous, easy to clean its initial cure period as well as temper-
managers often agree that joints and and maintain, long term durability, hard- ature change causes slight expansion
details are their biggest, most expensive wearing and good aesthetic appearance. or contraction. These forces may cause
problem when dealing with their current movement in the structure and between
flooring system. Sikafloor® flooring systems and different building parts.
Sikagard® wall coating systems do not
Therefore, it is ideal in food and beverage support the growth of bacteria or fungus. Since the joints are the most susceptible
facilities to provide surface solutions As anti-microbial coating, such products areas in flooring applications, the proper
with hygienic, jointless connections. prevent the growth of bacteria on the planning and design of a floor joint, has
Sika provides liquid-applied flooring surface, thanks to the material consti- to be performed with specific precau-
system solutions which cure to provide a tution and lack of joint crevices. Because tions to prevent the future damage.
completely seamless, smooth floor with they are completely seamless, there are Sika® FloorJoint and Sikaflex® sealing
not cracks, gaps or joints. no hiding places for dirt and bacteria. solutions for floor joints are designed to
Thus, it is easier and faster to clean and
maintain a hygienic environment.

Sikafloor® PurCem® DRAINAGE CHANNEL –

THERMAL EXPORURE AND DYNAMIC LOADING
Sikaflex® joint sealing
Sika® backing rod
Sikafloor® Purcem®
Anchoring groove
40 MM.

30 MM.

Drainage channel or
outlet with adhesive
steel flange
Concrete slab
N° 900_81_050_C_201604

0 10 20 40 MM

@YourSurface
50 Issue #2 | 2016 Sika Services AG
Tüffenwies 16
DETAIL FOR FLOORING
Sikafloor® PurCem® Drainage Channel - Thermal Exposure and Dynamic Loading
8048 Zürich April 2016, Version 01.03
Switzerland Available in: Revit (.rvt), AutoCAD (.dwg), Adobe (.pdf)
Tel: +41 58 436 4040 Template. For internal use only.
www.sika.com xxxx
 hygienically seal surfaces, with specific
joint movement and mechanical wear
resistance from traffic and structural
movement. Water, aggressive cleaning
agents and sanitizers used in food and
beverage processing facilities also can
impact the durability of floor joint seal-
ants. Therefore, they must have suitable
mechanical strength, chemical resistance
and excellent adhesion. Precise require-
ments are dependent on the function
and location of the respective joints.

As shown in detail drawing and image,

the radius cove is a standard Sika detail
which is free of joints and makes a prac-
tically maintenance-free, smooth curve
transition. Such coving is required at
the floor to wall connection and other
horizontal to vertical junction in food
processing areas. Floor-wall coating with flexible joint sealing
N° 900_81_022/023_C_appl_0812 4 1:2 N° 900_81_017_C_appl_0812

Sika flooring experts provide tailored Sikafloor® FLOOR-WALL COATING

detail drawings and advice for joint CONNECTION WITH RIGID COVE
sealing solutions according to each
unique situation. Sikagard® finishing
Sikadur® or Sikagard®
levelling mortar
For movement joints in floors, for
Concrete wall
example between a freezer and produc-
1. Concrete slab Sikafloor® coating system
tion area, Sika has a new innovative joint 2. Crack cut open and troweled off Sikafloor® coving mortar
profile solution Sika® FloorJoint, which 3. Sikafloor® Primer (epoxy) with Concrete slab
Corporate Template
fabric lining, width ca. 30 cm,
can be seamlessly connected to any thickness ca. 1 mm Metric
Sikafloor® resin flooring system and can 4. Sikafloor® system

be made watertight when combined with

Sikadur® Combiflex SG System.

Sika® FloorJoint S FLOOR MOVEMENT JOINT

Sika® FloorJoint S
Sikadur®-30 Normal or
Sikadur®-31 CF Normal
Sikaflex® sealant
Refurbishment of a crack - immovable crack Floor-wall coating with rigid fillet
N° 900_81_021_C_appl_0812 3 1:2 Masking tape Sikafloor® system
N° 900_81_016_C_appl_0812
Screed edge stripping or Existing substrate
backer rod

3 CM MAX.

@YourSurface
Sika Floor Joint S
2 1:2 N° 900_81_017_C_0315
Issue #2 | 2016 51
 REGULATIONS AND CERTIFICATION
IN FOOD AND BEVERAGE FACILITIES
Thousands of pages in many countries regulate various aspects
of food law. Yet, it’s surprising to find how slim those pages are
regarding the design and construction for food processing plants.

The regulations for floors, walls and ceilings are even slimmer. to be made in ways that make adequate surface drainage
The main requirements for floors concern cleaning, personnel possible. The regulations do not differ much between different
safety and surface drainage. continents and regions. Depending on perspective, this
can either be a blessing or a curse: a company is given more
For example, the EU the Regulation 852/2004 Annex II Chapter freedom in design of the facility, but on the other hand, has
II says that the surfaces of floors, doors and walls need to be less specific requirements on how to operate safely.
maintained in sound condition and that they should be easy to
keep clean and, when necessary, easy to disinfect. The legisla- There are a number of independent associations that have
tion states that “this will require the use of impervious, non- created certification and approval programs for food safety.
absorbent, washable and non-toxic materials.” The quality of flooring weighs in heavily to all of these stan-
dards and certifications. Sika is pleased to help you sort them
All well and good. A separate rule claims that the floors have out for your particular application:

@YourSurface
52 Issue #2 | 2016
INDEPENDENT CERTIFICATION OF SIKA FLOORING AND COATING

ISEGA Regulation (EC) No 852/2004 of the European Parliament and of the Council of 29 April 2004
­(Annex II Chapter II) on the hygiene of foodstuffs. ISEGA Test institute.

FDA & FSIS The Food and Drug Administration (FDA) and the United States Department of Agriculture (USDA)
Food Inspection Safety Service (FSIS) which share the primary responsibility for regulating food
safety in the United States. FSIS has responsibility over meat, poultry and some egg products. FDA
regulates all foods other than meat, poultry and some egg products.

HACPP HACCP (Hazard Analysis and Critical Control Points). Food production, storage, and distribution mon-
itoring system for identification and control of associated health hazards. It is aimed at prevention
of contamination before end-product evaluation.

CSM “Cleanroom Suitable Materials” (1 is the world’s first standardized product qualification according
to ISO 14644 and GMP standards for use in clean rooms. In food related areas: Biological resistance
test assessing the action of bacteria and mould on the material, according to ISO 846. Riboflavin
test assessing the clean-ability of the surface. according to “Clean-room Suitable Material” proce-
dure. Fraunhofer Test Institute.

1
“ Clean-room Suitable Materials” is the world’s first standardized product qualification according to the ISO 14644 and GMP standards
for use in clean rooms.

AgBB AgBB (AusschusszurgesundheitlichenBewertung von Bauprodukten) is a scheme for health-related

assessment of emissions of volatile organic compounds (VVOC, VOC and SVOC) from construction
products in Germany. The scheme has criteria for testing and assessment for VOC emissions from
construction products suitable for indoor usage. It sets quality standards and restrictions relevant to
VOC emissions for future production of construction products for indoor usage.

A+ ANSES. (The French Agency for Food, Environmental and Occupational Health and Safety) provides
collective expert assessment of applications for the marketing of pesticides and biocides, as well as
chemicals within the framework of the REACH regulations according defined procedure and criteria.
It issues marketing authorizations, following assessment work, of plant protection products, fertil-
izers and growing media, and their adjuvants.

*Information représentative des émissions dans l’air intérieur des

substances volatiles présentant un risque de toxicité par inhalation,
Campden BRI
sur une échelle de classe allant de C (fortes émissions) à A+ (très
faibles émissions)
Sensory evaluation of chocolate to test the taint potential of a flooring compound. Campden BRI
Test Institute.

@YourSurface
Issue #2 | 2016 53
 SIKA SOLUTIONS AND
SUSTAINABILITY
Limited resources, climate change, water, and infrastructure are
global megatrends which are re-shaping Sika’s markets and also
guiding Sika’s business. As an innovator and technology pioneer,
Sika thinks ahead and is committed to a better environment
through an integrated product approach.

Sika’s innovative solutions and our products sustainability Sika has always been a pioneer in supplying solutions to meet
are Sika’s contribution to the sustainability of your projects. the highest environmental standards and actively aligns itself
Being aware that environmental impacts occur at each stage to various green building certification programs, including
of the product life cycle, Sika uses Life Cycle Assessment LEED, BREEAM and DGNB. Sika is looking to genuinely provide
(LCA) methods according to the ISO 14040 series and Standard sustainable values and is a member of WBCSD, UNEP (SBCI)
EN15804 to provide quantitative evaluation of the potential and Responsible Care.
environmental impact of our products and services over their
entire life cycle. Sika sustainability solutions focus on:
́́ Durability of the building materials
́́ Very low VOC and particle emissions from Sika product
ranges to be tested and approved to the most stringent
global standards for emissions including AgBB, AFSSET, and
Natural Resources Raw Materials Produ
c ti
o M1, etc., plus they also have the lowest fire ratings.
́́ Ease of use and ease of maintenance once the products
n

Cradle to Gate
have been applied.
Cradle to Grave
́́ Development of recycling processes and facilities for Sika
Application

products.
Promotion of alternatives in specifying refurbishment solutions
to contribute to a sustainable future with far less investment
and resources than a rebuild.
ce
nan
Waste End-of-Life Use and M a i n t e
We believe that in the future, this positive approach will
remain crucial to Sika’s success in the global market, and we
will continue to anticipate and respond strongly to major envi-
ronmental challenges ahead, which will undoubtedly continue
to result in better and more sustainable solutions for all areas
Therefore Sika works to develop: of construction.
́́ Energy-efficiency solutions
́́ Climate protection solutions
́́ Material-efficiency solutions
́́ Water-efficiency solutions
́́ All of which can contribute towards sustainable construction

@YourSurface
54 Issue #2 | 2016
LIFE-CYCLE ASSESMENT (LCA) RESULTS FOR POPULAR Sikafloor® Purcem® FLOORING SYSTEMS
USED IN FOOD INDUSTRY
The performed LCA* shows that the Sikafloor® PurCem® food and beverage industry. In addition the proven extremely
hybrid flooring has half lower Cumulative Energy Demand (CED) low VOC emission values confirm the possibility to work and
compared to other flooring solutions like High Duty Ceramic apply the product close to foods stuff during the production
Tiles. This added with the life expectancy of fifteen years operations.
without any refurbishment - especially interesting property for

LCA RESULTS FOR POPULAR FLOORING SYSTEMS

Cumulative Energy Demand (CED) for 1 m2 flooring system [MJ/m2], Global Warming Potential (GWP) for 1 m2 flooring system [kg CO2-eq./m2],
15 years 15 years

700 35

600 30

500 25

400 20

300 15

200 10

100 5

Competitive Technology
Sikafloor® Sikafloor® Sikafloor® Heavy Duty Sikafloor® Sikafloor® Sikafloor® Heavy Duty Top Sealer
PurCem® PurCem® MultiDur Ceramic PurCem® PurCem® MultiDur Ceramic Base Coat
HM-20 HS-21 EB-24 Tiles HM-20 HS-21 EB-24 Tiles Primer
Adhesive

Note: Materials for repairs are included where they are required to provide the defined life expectancy
(Sika ComfortFloor® PS-23, Sikafloor® MultiDur EB-24)

*Life Cycle Assessment (LCA) is a standardized method to assess and compare the inputs, outputs and potential environmental impacts of products and
services over their life cycle. LCA’s are increasingly recognized as the best way to evaluate the sustainability of products and systems. As a standard
approach Sika evaluates all 8 impact categories. However for flooring, categories considered to be most relevant include: Cumulative Energy Demand
(CED), Global Warming Potential (GWP), and Photochemical Ozone Creation Potential (POCP).

@YourSurface
Issue #2 | 2016 55
 Sikafloor® SOLUTIONS –
A SAFE AND DURABLE MATCH
FOR YOUR SPECIFIC NEEDS

>

@YourSurface
56 Issue #2 | 2016
What makes a floor a Sikafloor®? At Sika, the global leader in innovative
flooring solutions, we listen carefully to what our customers want and need,
stay abreast of changes that can impact your business, and make significant
­investments in research, development and testing in order to bring you trusted,
engineered solutions based on evidence and best practices. Our time-tested,
proven approach is rooted in more than 100 years of experience developing
technologies used in flooring as well as concrete production, below-ground
­waterproofing, roofing, sealing and bonding, and other industrial applications.

We know that your business has its own unique flooring

­requirements in terms of impact resistance, rolling load resis-
tance, wear resistance, safety regulations, antistatic perfor-
mance, chemical or fire resistance and, increasingly, quick and
efficient installation. Because our products can be customized
to meet your technical requirements while still complying with
government regulations, you’re assured of getting excellent
solutions that have only the characteristics you want and need.

Sika is a global expert in all core technologies commonly used in

our specialty area of seamless flooring. And, all Sikafloor® solu-
tions are developed and manufactured according to industry
standards as well as our own strict standards for quality assur-
ance and business ethics. To ensure the perfect solution for
your business, we offer several flooring families for you to
choose from. The families are based on core technologies.
Variations within each family allow you to find solutions fine-
tuned to your individual needs. All of the families are bonded
together by our core flooring values: seamless solutions for
your needs, innovative designs, durable and sustainable perfor-
mance by offering more value at less impact, and full profes-
sional support by expert field personnel who are not only the
best at what they do but who also take great pride in their work
and care about your project.

We design every seamless Sikafloor® product using liquid-

applied synthetics or synthetic-cementitious-hybrids. Our
synthetic solutions are ideal for a wide variety of applications
which is why you find them in industrial buildings, food and
pharmaceutical facilities, car parks, schools, libraries, hospi-
tals, shopping malls, museums, apartment building balconies,
private residential properties and other settings.
Whether you’re a building tenant, owner or applicator, Sika has
Our cementitious flooring solutions are designed for ready- you covered. In addition to our array of product offerings, we
to-use and subfloor preparation applications. For time-critical can supply you with industry certifications, proof of product
projects, we offer a unique technology that reduces the waiting performance and a global network of flooring specialists. For
time for moist concrete to dry – our Sikafloor® EpoCem® inter- applicators, we also offer training programs to ensure proper
mediate layers can be installed directly on green and damp installations. We do these things because we believe in Building
concrete. Trust.

@YourSurface
Issue #2 | 2016 57
 SIKA PRODUCT OFFERINGS:

Sikafloor®MultiDur solutions approved for cleanroom usage;

Epoxy flooring systems by Sika, a global and electrostatic discharging, dissipative
standard. Your workhorse for heavy-duty and electrically conductive flooring. For
performance, these flooring systems more basic flooring use and high perfor-
offer excellent mechanical strength, mance wall coating needs, we offer
wear-resistance and chemical-resistance. water-borne coating systems.
Although seamless floors, by definition,
are aesthetically pleasing, color and Sikafloor® MultiDur solutions are
design are typically not our customers’ commonly found in:
major driver in choosing these flooring ́́ Storage, logistics and sales areas
options. Rather, functionality and ́́ Production, processing and cleanroom
delivering long-lasting performance is areas (dry and wet)
where these floors excel. Choose from ́́ Ground-bearing decks, car parks and
smooth, textured, broadcasted (slip- parking garages
resistant) and mortar finishes to ensure ́́ Commercial, public and residential
the usability, safety and cleaning regime areas
best fitting your needs.

Within the Sikafloor® MultiDur family

you will find special solutions with
extremely high chemical resistance;

Sikafloor® DecoDur
Decorative epoxy flooring systems by
Sika. These added design options for
heavy-duty flooring are perfect for proj-
ects where you want more than a tradi-
tional, uni-color design and need the
performance of an epoxy floor. Within
the Sikafloor® DecoDur family, we offer
flooring solutions with different grades
of mechanical and chemical resistance,
all in a speckled design. Patterns range
from a granite effect up to a larger full-
flake design and are available in a variety
of colors.

Typically, Sikafloor® DecoDur floors are

installed with a smooth or lightly broad-
casted surface texture. At your prefer-
ence, we can finish the floor with a matte
sealer designed to withstand common
household and light-industrial chemicals
or a tougher, more chemical-resistant,
glossy finish.
Sikafloor® DecoDur floors are commonly ́́ High-pedestrian traffic zones in
found in: commercial and institutional build-
́́ Life science facilities ings
́́ Laboratories ́́ Food courts

@YourSurface
58 Issue #2 | 2016
 Sikafloor® MultiFlex
Polyurethane flooring systems for
heavy duty and industrial usage by Sika.
­Sikafloor® MultiFlex systems are known
for their higher elasticity which allows
for crack-bridging designs. Further,
these floors excel in absorbing base floor
movements.

Sikafloor® MultiFlex solutions include

designs installed directly on top of elastic
waterproofing membranes and are avail-
able with or without special surface
protection. These floors are installed in
smooth, light broadcast and heavy broad-
cast (high anti-slip) designs.

Sikafloor® MultiFlex can commonly be

found in:
́́ Storage, logistic and sales areas
(raised floors)
́́ Production, processing and cleanroom
areas (dry and wet)
́́ Car parks, intermediate and top decks

Sika ComfortFloor®
With decorative, polyurethane flooring
systems for commercial and residen-
tial applications by Sika, perfection has
never been so close. Global technology
leadership in industrial and resilient
flooring comes together in our Sika
­ComfortFloor® family, offering seamless,
high-end aesthetics for even the most
discerning clientele. An environmentally
friendly solution, Sika ComfortFloor® is
mainly based on natural oils and organic
raw materials. Its backing – comprised
of resilient, acoustic isolation pads –
are made of recycled rubber and foam
particles.

Sika ComfortFloor® products offer

nearly unlimited design freedom. They a light, anti-slip surface texture for use museums, libraries and hospitals
are typically installed in a matte finish in wet areas such as showers and toilet ́́ Commercial buildings such as shop-
and are available in 72 standard colors. rooms. All products offer very high color ping malls, hotels, office buildings and
Custom colors are also an option, as are stability. restaurants
two-tone “concrete-look” designs and ́́ Residential buildings of high-end,
the ability to create your own floor art. Sika ComfortFloor® solutions are modern design
Additional options include broadcasted commonly found in: ́́ Therapeutic, restorative and exercise
colored flakes for a speckled design and ́́ Institutional buildings such as schools, facilities, such as yoga or spa spaces
 Sikafloor® MonoFlex
One-component, polyurethane flooring
solutions for easy installations, by Sika.
Sikafloor® MonoFlex flooring solutions
have earned their excellent reputation
based mainly on their performance as
a waterproof finish for balconies, walk-
ways and staircases with pedestrian
traffic. These moisture-triggered solu-
tions are true innovations in terms of
sustainability and ease of application.

Upon request, broadcasted colored flakes

can be added for a speckled design. A
light or medium anti-slip surface texture
can also be provided. All products in this
family offer very high color stability.

Sikafloor® MonoFlex solutions are

commonly found in:
́́ Balconies
́́ Pedestrian walkways and staircases

Sikafloor® PurCem® Sikafloor® PurCem® Gloss is the latest Sikafloor® PurCem® solutions are
Polyurethane cementitious hybrid ­innovation to our Sikafloor® PurCem® commonly found in:
flooring systems by Sika. These innova- family. This product’s glossy finish allows ́́ Food and beverage processing facili-
tive flooring solutions deliver extreme for significantly easier floor cleaning. ties
performance in terms of mechanical and Specified with a smooth surface finish ́́ Professional kitchens
chemical resistance as well as reduced and in a low- to medium- thickness, this ́́ Cool storage areas
environmental impact. Because they’re solution can be an alternative to some ́́ Heavy-duty processing areas, espe-
durable, low maintenance and available Sikafloor® MultiDur products. cially wet processing
with resurfacing options, our versatile
Sikafloor® PurCem® range of products
is gaining global appreciation and can be
found in a wide variety of heavy-duty
­applications. The special core technology
of an elastic resinous binder reacting
with cementitious fillers is what makes
this product family resistant to high
temperature variations, even thermo
shocks for certain designs. Installation on
damp concrete surfaces is possible with
­Sikafloor® PurCem®.

Typically, Sikafloor® PurCem® floors

are installed in a light or heavy anti-slip
broadcast or in a full mortar build-up to
ensure high performance in wet areas. A
smooth/light-textured surface finish is
available for dry areas.

@YourSurface
60 Issue #2 | 2016
Sikafloor® Pronto
Methacrylate (P.M.M.A.) flooring
systems that speed up installation times
to the maximum, by Sika. Our Pronto
family is known for it’s high resistance
to a wide variety of uses. The super-fast
curing time of these synthetics allows
for super-quick refurbishments, though
proper ventilation is required during
installation to avoid inconveniences from
odors.

When applied to areas with pedestrian

traffic, Sikafloor® Pronto surfaces are
typically installed in a smooth or light
broadcast finish. A colored-flake broad-
cast finish can be provided upon request.
A heavier broadcast finish is available
for applications where there is vehicle
­traffic.

Sikafloor® Pronto solutions are ́́ Processing areas ́́ Animal facilities

commonly found in: ́́ Pedestrian walkways, such as balco- ́́ Multi-story and underground car
́́ Commercial kitchens nies and staircases parks

Sikagard® WallCoat need more than just paint, our family finishing, including chemical resistance
A wall coat that blends specific, engi- of Sikagard® WallCoat performance and and heavy-duty mechanical resistance.
neered performance requirements with decorative wall coating systems delivers
decorative designs, by Sika. When you unique benefits for demanding surface Our wall coat has the ability to withstand
chemicals used in cleaning regimes and
in-film preservatives providing finishes
that do not promote the development
of fungi, bacteria and other micro organ-
isms. Our wall coat systems come in an
array of colors, many of them match
specified Sika florring product colors.
­Sikagard® WallCoat solutions do it all
easily.

Sikagard® WallCoat solutions are

commonly found in:
́́ Cleanroom certified areas
́́ Food and beverage processing facili-
ties
́́ Hospitals and laboratories
́́ Concrete surface protection
́́ Tunnels
́́ Commercial, institutional and resi-
dential interior finishing
 Sikafloor® HardTop
Concrete surface hardening, curing
and sealing and heavy-duty industrial
screeds, by Sika. Our dry shake S
­ ikafloor®
powders are broadcasted directly onto
the fresh concrete – before the power-
float finish is applied – to create an
extremely hard-wearing, monolithic
concrete floor. Additional performance
can be achieved through various liquid-
applied surface hardeners, curing
compounds and surface sealers.

Sikafloor® HardTop solutions are

commonly found in:
́́ Storage, logistics and sales areas
́́ Non-critical, heavy-duty industrial
areas such as dry processing facilities
́́ Car parks, parking garages

SikaCeram® StarGrout This new product offers great benefits perfect finish with the neutral silicone
SikaCeram® StarGrout is the new gener- to the tile setter and craftsman, e.g. Sikasil® C with the same color, name and
ation of epoxy grout classified R2T outstanding workability, easy to clean shade.
and RG according to the tile adhesive off, reduced odor, long lasting, plus a
Standard EN 12004 and the tile grout
Standard EN 13888. This premium tile
grout is suitable for grouting all kinds of
ceramic tiles, mosaic, marble and natural
stone, for both interior and exterior use
on joints between 1 and 15 mm. Thanks
to its extremely high mechanical and
chemical resistance it is a perfect choice
for places where absolute hygiene plays
a deciding role, in either residential or
commercial areas such as swimming
pools, laboratories, industrial kitchens
or the food industry.

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62 Issue #2 | 2016
Sika® FloorJoint systems and can also be made watertight
The sound and feeling of rumbling over by using Sikadur® Combiflex SG System.
crossing joints in warehouses and traf- The installation of the panels is easy and
ficked areas is familiar to most people. fast providing extremely short down-
It can feel uncomfortable and cause irri- time. The system fits perfectly to fast
tation for ears and body. Innovative joint space refurbishment jobs. Sika® FloorJoint
panel Sika® FloorJoint offers the perfect systems have good chemical resistance,
solution with ultra-thin and almost invis- are totally seamless to surrounding floor
ible joint profiles for reducing the noise surface and absolutely corrosion-free,
and vibration over the joints. The profiles perfect solution for food processing
are installed on the same surface level environment.
as the floor, which means no thresholds.
Another functional benefit of the system Main uses in:
is the reduction of impacts on the vehicles ́́ Warehouses
crossing the joint, meaning the significant ́́ Industrial floors
cost saving in spare parts and mainte- ́́ Parking areas
nance of the forklifts. ́́ Commercial and public buildings

Sika® FloorJoint has two profile options,

Sika® FloorJoint PD and S, which are
compatible with Sikafloor® flooring

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Issue #2 | 2016 63
 FULL RANGE SOLUTIONS FOR
A WATERTIGHT AND SECURE
BUILDING ENVELOPE

1. HIGH PERFORMANCE ADMIXTURES FOR CONCRETE Sika has a proven track record of providing durable and reliable
Concrete structures and elements including the founda- corrosion and fire protection coatings on steel structures for
tion, basement, walls, columns, beams and floor slabs form over 50 years. Our coating systems are available in different
the main part of the overall building evelope. Sika’s solution colors and comply with the latest National and International
includes concrete admixtures which increases the performance Standards including ISO EN 12944 for steel corrosion protection,
factors of such concrete components, such as strength, work- and ISO EN 13381-8 for fire protection.
ability, watertightness and many other features. Sika experts
also provide tailored solutions for architects to create special 6. DURABLE AND LONG LASTING ROOFING
design effects when specifying concrete as a key visual design A long-lasting watertight roof is essential for the reliable
element in their projects. operation and sustainability of a plant. Rain, snow, wind uplift
forces, sun light, and many other environmental influences can
2. WATERTIGHT BASEMENTS AND OTHER BELOW GROUND cause failure of the roof system. This results in leaking and
STRUCTURES damage which require costly repairs, and possibly re-roofing.
In food and beverage facilities, the ground bearing areas need As the global leader with a proven record of over 50 years, Sika
to be waterproofed. Sika has over 100 years of experience in produces high quality and long-lasting Sarnafil® and Sikaplan®
providing waterproofing solutions. The selection of the most polymeric membranes, plus SikaRoof® MTC liquid applied
appropriate waterproofing concept and system for any specific membrane that meet the specific needs and budgets of roofing
project is dependent on many factors, and it is important to for health-care facilities.
involve a qualified waterproofing specialist at the early stages
of design. Your local Sika Technical Services Department can Sika supplies solutions for the new-build and refurbishment of
provide expert advice and proper solutions to all your problems. the following roofs:
́́ Exposed roofs
3 & 4. SEALING AND BONDING FOR WATERTIGHT FACADES ́́ Gravel ballasted roofs
AND WINDOW INSTALLATION ́́ Green roofs
Energy efficiency requirements for exterior walls are becoming ́́ Helipads
more stringent, strongly influencing building standards world- ́́ Solar roofs
wide. Sika has developed sealing and bonding technologies and ́́ Balconies
systems for facades to help designers meet higher energy effi-
ciency and environmental requirements, whilst ensuring safe,
economical installation and also reducing overall construc-
tion time. Sika works in close cooperation with leading facade
designers and manufacturers using the latest material tech-
nologies for all types of facade construction.

5. CORROSION AND FIRE PROTECTION OF STEEL

­STRUCTURES
Steel structures in buildings all need to be protected against
corrosion caused by exposure to the surrounding environment.
In manufacturing facilities, they also have to meet stringent
building regulations for fire protection.

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64 Issue #2 | 2016
INTERIOR ENVIRONMENTS CAN ONLY RUN
PERFECTLY WHEN PROTECTED BY A P ­ ERFECTLY
TIGHT BUILDING ENVELOPE. TAKE CONTROL OF
YOUR ENVIRONMENT WITH BUILDING ENVELOPE
SOLUTIONS FROM SIKA.

3
4
5 1

SOLUTIONS FOR:

1 2 3 4 5 6
Admixtures for Basement Sealing and bonding Facade joint Fire and corrosion Roofing
concrete waterproofing for glazed facades sealing/Window protection for steel
installation structures

@YourSurface
Issue #2 | 2016 65
 SIKA AS A RELIABLE AND
­INNOVATIVE PARTNER IN THE
­CONSTRUCTION OF FOOD &
BEVERAGE FACILITIES
Sika is a specialty chemicals company with a leading position in the
­development and production of systems and products for bonding,
­sealing, damping, reinforcing, and protection in the building sector
and the motor vehicle industry. Sika has subsidiaries in more than 90
­countries around the world and manufactures in over 160 factories.

100 YEARS OF EXPERTISE WHAT MAKES SIKA SUCCESSFUL IS

Our reputation for quality and reliability is virtually unmatched, THE COURAGE FOR INNOVATION
and is illustrated through a comprehensive portfolio of problem 873 employees globally are dedicated to research and develop-
solving products that have been employed for many years in a ment. Sika’s success and reputation is based on our long-lasting
diverse range of applications. Whether we are waterproofing tradition of innovation.
your basement or your roof, protecting your floors and wall,
sealing your skyscraper or your car, or working with you on your Accordingly, the core of Sika business is the innovation manage-
building, you will see why we are renowned for Building Trust. ment and the focus on developing quality products and the best
For the full range of solutions from basement to roof, please solutions for customers. Sika Technology AG in ­Switzerland
refer to our brochure on manufacturing facilities. takes the lead in long-term research programs for the whole
Sika Group, whilst the responsibility for the development of
WORLDWIDE PRESENCE FOR CUSTOMERS new solutions sits with our 20 Global Technology Centers plus
Sika has a long track record of success as a complete system and 18 Regional Technology Centers worldwide. New products and
problem solution provider on many different food & beverage systems are also developed on a regional level to meet local
facility projects all around the world. Please visit the “­ reference” markets’ specific needs and requirements.
section on www.sika.com to see a selection of these projects.
With extensive technical expertise and solid practical experi- MORE VALUE, LESS IMPACT
ence on every continent and in all types of climate and environ- Sika is committed to pioneering sustainable solutions to
ments, Sika is a highly qualified and reliable partner for all of address global challenges, and to achieve this safely at the
your projects. Sika has highly professional technical and sales lowest impact on resources. Creating and increasing value while
teams to support our customers and their clients. These teams reducing impacts – that is the goal. Our strategy fully inte-
include qualified engineers and technicians with expertise grates sustainability into all of our business processes, and we
in all of the relevant technologies and applications, together strive to create value for our customers and partners along the
with technical service engineers that have extensive practical whole supply chain and throughout the lifespan of our products.
installation and on-site training expertise to help ensure that The value created far outweighs the impacts associated with
the work is completed correctly and is ‘right the first time.’ production, distribution and use.

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66 Issue #2 | 2016
KASPAR WINKLER SIKA HAS PROVIDED WATERPROOFING EVERY YEAR SIKA SUPPLIES ENOUGH ROOF
FOUNDED SIKA IN ­SOLUTIONS FOR MORE THAN MEMBRANES TO COVER THE

1910 100 YEARS WHOLE OF

THE FIRST PRODUCT – Sika®-1 –
IS STILL ON THE MARKET
MANHATTAN
CORE COMPETENCIES:

BONDING, SEALING, DAMPING, REINFORCING

AND PROTECTING LOAD-BEARING STRUCTURES
IN BUILDING AND INDUSTRY.

SIKA HAS WORLDWIDE EVERY YEAR SIKA FILES

98 TECHNOLOGY 70 NEW PATENT

­CENTERS ­APPLICATIONS
SIKA’S CLEANROOM FLOORING SYSTEMS RELEASE WITH

1,000 TIMES 84 AWARDS

LESS EMISSIONS IN 16 YEARS, SIKA IS THE COMPANY WITH THE MOST
CONCRETE REPAIR PROJECTS AWARDED WORLDWIDE
THAN STANDARD LOW VOC SYSTEMS

SIKA HAS SUBSIDIARIES IN SIKA HAS SIKA ACHIEVED TOTAL SALES OF

93 COUNTRIES 17,000 CHF 5.49

AROUND THE WORLD
­EMPLOYEES ­BILLION IN 2015
ALSO AVAILABLE
FROM SIKA

FOR MORE SIKA FLOORING

INFORMATION:

WE ARE SIKA
Sika is a specialty chemicals company with a leading position in the
­development and production of systems and products for bonding,
sealing, damping, reinforcing and protecting in the building sector and
the motor vehicle industry. Sika’s product lines feature concrete admix-
tures, mortars, sealants and adhesives, structural strengthening sys-
tems, industrial flooring as well as roofing and waterproofing systems.

Our most current General Sales Conditions shall apply. Please

consult the most current local Product Data Sheet prior to any use.

SIKA SERVICES AG Contact

Tueffenwies 16 Phone +41 58 436 23 68
CH-8048 Zurich Fax +41 58 436 23 77
Switzerland www.sika.com