1. URETHANE CEMENTS or EPOXY COATINGS FLOORING IN A BREWERY Presented by Norm Klapper PEC – Boulder, Colorado

2. Presentation Outline Why coat concrete floors? When is the best time to coat? Contractor selection Concrete preparation Essential installation details, thickness Urethane cement or epoxy topping? Typical installation applications Key physical properties of each formulation Life cycle comparison and recommendations Summary and conclusions

3. Issues Unique to Breweries Wet, humid conditions Presence of caustic and chlorine-based CIP and wash down agents Thermal shock: cold floors (<50°F) washed with hot, 180 °F water Presence of yeast which if trapped in crevices, cracks or under coatings can easily cause delamination Tough food grade standards apply, regulated industry Heavy wheeled traffic, impacts from equipment, kegs, fork lifts, pallet jacks Operations usually 24/7, little downtime allowance Public viewing or access to brewing areas and need for aesthetics in a production area Health and safety for personnel, slippery conditions

4. Why Coat Concrete Floors? Protection from Chemical Attack CIP daily wash down, caustics, chlorine Brewery waste products Yeast, carbonic acid Protection from Mechanical Wear Impact Wear from Pallets, etc. Prevent cracking, abrasion

5. Why Coat Concrete Floors…..cont. Provide Slip Resistance for Safety Minimize wet, slippery conditions Aesthetics Provide an appealing and professional look Cleanability & Maximize Service Life Monolithic substrate and smooth transitions to drains

6. Second Street Brewing – Sante Fe

7. Epoxy with Decorative Quartz

8. When to Coat? New Floors Best Open area New Construction – BEST forContractor No contamination Floor, drains, etc. not compromised No equipment legs Old Floors With existing coating? REMOVE ALL – clean warranty Without existing coating? Use correct preparation techniques

9. Contractor Selection Contractor MUST be certified by the manufacturer of the coating – suggest you verify Contractor must have a proven track record of successful projects, delivered on time. Contractor must offer a JOINT WARRANTY with the manufacturer which protects the Owner/End-User Get References and check them!

10. Concrete Preparation All coatings require competent and thorough surface preparation Mechanical Diamond Grinding Scarifying Shot Blasting Crack Chasing Detailing – Keyways, Drains, etc. Profile MUST be equal to an SP5 – SP6

11. Concrete Preparation

12. SP5 and SP6 PROFILES

13. Concrete Preparation….cont. All coatings require competent and thorough surface preparation Chemicals are supplements to mechanical techniques Acid Etching Chlorine or Caustic Sanitizing Extensive hot water washing Additional Techniques (Optional) Flaming (Weed Burners) High pressure air / vacuum for standing water removal

14. Timing of Installation Concrete age & moisture content 28 Day Rule Vapor barriers under new slabs - VERY important Moisture in Concrete Run Calcium Chloride Test Plastic Sheet Test – ASTM D4263 Relative Humidity Meters (RH Meters) High early concrete Steel trowel finish Cure and seal? – NOT recommended removed entirely by mechanical prep techniques

15. HAND TROWELED – EITHER EPOXY or URETHANE CEMENT

16. Installation Details – Perimeter Key

17. Installation Details – Control Joint

18. Installation Details – Crack Repair

19. Installation Details – Expansion Joint

20. Installation Detail – Corner Expan. Joint

21. Installation Details – Metal Base Plate

22. Installation Details – Drain

23. Installation Details – Cove/Exp Joint

24. Installation Details – Spoon Cove Base

25. Installation Details – Cant Cove Base

26. Installation Details – Pipe Protrusion

27. Installation Details – Bolt Holes

28. Installation Thickness All formulations available in…… Thin film (3-15 mils) Double broadcast slurries (1/8” - 125 mils) ¼” troweled – BEST OPTION! Slope to drain – as thick as needed up to 1” or more, (1/8” in 10’) – CHECK FLOOR FIRST! Self-Leveling formulations – tougher on sloped floors Berms – created using same materials or filler patch formulations – saves $ but takes longer Cove or no cove? Spoon or “cant” type?

29. Urethane Cements / Epoxy Coatings ALL providers of URETHANE CEMENTS have similar formulations ALL have similar: Working Time Temperature Resistance Chemical Resistance Bond Strengths to substrates

30. Urethane Cements / Epoxy Coatings In Contrast, EPOXY COATINGS all have great variations in formulations WIDE VARIATION in all characteristics Working Time Temperature Resistance Chemical Resistance Bond Strengths to substrates

31. WHY THE CONTROVERSY? Great variations in epoxy formulations and therefore varied application success Many offered non-resin rich, top-coated (grout-coated) dry systems with high compressive strengths (>10- 15,000 psi, 2-3x’s concrete!) Harder, more brittle materials with less thermal shock resistance, reduced life spans (1-2 years!) Urethane cements “took up the slack” and offered viable alternatives Similar coeff. of thermal expansion to that of concrete, less likely to delaminate under thermal shock

32. WHY THE CONTROVERSY….cont Early epoxy failures led to: Rise in Polyesters, Vinylesters, Methylmethacrylates (MMA) – all with high odor Followed by lower VOC, more resin-rich epoxies, more impervious to liquids and subsequent failures. Newer, high performance epoxy formulas which maintained resin-rich, LOWER compressive strengths and greater chemical resistance, thermal shock resistance Flexibilized epoxies have been around decades longer than Urethane Cements and these have had wide success

33. Flexibilized ¼” Epoxy

34. COMPARISON of URETHANE & EPOXY TOPPINGS 1 (Assumes 1/4" Thickness, Flexible, Resin Rich Epoxies, Average Values) PROPERTY URETHANE CEMENTS EPOXY TOPPINGS ASSUMPTIONS / COMMENTS Compressive Strength (psi) 11,000 5,200Formula Dependant Tensile Strength (psi) 1,800 2,030 Tensile Elongation (Filled)N/A3%Aggregate Filled Bond Strength (psi)>1000 psi ???Proper Preparation Impact Strength (in-lbs)120160Aggregate Filled Shore Hardness (D)8575 Aggregate/Liquid Ratio4.75 : 15 : 1By Weight

35. COMPARISON of URETHANE & EPOXY TOPPINGS 2 (Assumes 1/4" Thickness, Flexible, Resin Rich Epoxies, Average Values) PROPERTY URETHANE CEMENTS EPOXY TOPPINGS ASSUMPTIONS / COMMENTS Service Temperature212 °F180 °F Normal Operating Conditions Max Temperature400 °F (Hot Oil)200 °FBrief Excursions Chemical ResistanceExcellent Acid Resistance180 °F140° F Wear /Abrasion ResistanceExcellent Broadcasted Aggregate Crack ResistanceModerateModerate to Good Epoxy has greater tensile elongation Thermal ShockGoodExcellent

36. COMPARISON of URETHANE & EPOXY TOPPINGS 3 (Assumes 1/4" Thickness, Flexible, Resin Rich Epoxies, Average Values) PROPERTY URETHANE CEMENTS EPOXY TOPPINGS ASSUMPTIONS / COMMENTS Application Techniques Hand or Power Troweled, Slurry Working Time10-20 Minutes30 - 60 minutesTemp Dependent Cure Times4-8 Hours6-18 HoursTemp Dependent Ease of InstallationDifficult to ModerateEasy to Moderate Troweling more challenging; Slurry systems easier Installation Temperatures55°F - 80°F38°F - 90°FVarious Formulations Thickness1/8" - 3/8" Any Thickness

37. COMPARISON of URETHANE & EPOXY TOPPINGS 3 (Assumes 1/4" Thickness, Flexible, Resin Rich Epoxies, Average Values) PROPERTY URETHANE CEMENTS EPOXY TOPPINGS ASSUMPTIONS / COMMENTS TypeResin-Rich 5 : 1 By Weight Top CoatingOpt. (Req’d for Aesth)OptionalFor Slurries or Aesthetics Priming RequiredRecommendedNo (optional) Life CycleExcellent AestheticsFinishes DullFinishes ShinyBoth can be top coated Cost / SF (Installed)$5.50 - $10.00$5.50 - $8.50 Flat or Concrete sloped, 1/4" Topping Cost / SF (Installed)$8.00 - $15.00 Sloping to Drain (1/8" in 10 Feet)

38. Similar Installation Techniques Mixing – virtually the same Troweled – hand or power-troweled Screed method – using screed boxes or bars Slurry system in one or two lifts Uses more resin compared to troweled Finished “as-troweled” Final coat back-rolled, seeded, top coated or not top coated Neither system requires top coating Top coating mostly for aesthetics

39. Anheuser-Busch

40. Urethane Cement – Screed Box

41. Installation Characteristics OPEN (WORKING) TIMES Urethane Cement – open time, 15 minutes Epoxy Topping – open time, 45-60 minutes CURE TIMES Urethane Cement – cure time, 8 hours (Fixed, not changeable) Epoxy Topping – temperature dependent– cold cure (6 hours), fast cure (8 hours), regular cure (14-18 hours)

42. Final Textures & Colors Optional Textures – determined by type and size of sand media Silica Quartz Aluminum Oxide Grit / Mesh Sizes – from 16 to 30 Trade off between slip resistance and cleanability – VERY subjective Strongly suggest sample texture offered for evaluation and approval purposes Maintenance and safety concerns need to be balanced

43. Recommendations? URETHANE CEMENTS Higher temperatures >220 degrees F Chemicals at higher temperatures New construction for open areas due to less open time for working/application

44. EPOXY TOPPINGS Reasonable temperatures – 180 degrees max Cost concerns – easier to apply, smaller crews, with usually somewhat lower installed cost Single step – finishes with higher gloss, no top coat Recommendations?

45. SUMMARY Both urethane cements and epoxy coatings provide excellent concrete protection and safe working surfaces Urethane Cements are formulated virtually the same – Epoxy Coatings vary greatly Epoxy Coatings (resin rich) have greater open times and are easier to apply – also do NOT require a top coat to finish with high gloss Can be applied in one-step, less time

46. SUMMARY…..cont. Urethane cements usually require a primer coat while resin rich epoxy coatings do not and therefore can be applied in ONE-STEP Epoxy Toppings have a lower operating temperature when compared to Urethane Cements Epoxy Toppings have greater bond strength to a wider range of substrates

47. SUMMARY Epoxies vs. Urethane Cements Both are “flexibilized”, resin rich ¼” and will do the job Urethane cements when temps > 212°F or if hot acids hit floor (>140°F-160°F) Epoxies have better damp adhesion Epoxies have better adhesion over quarry tile “As-Troweled” epoxy better gloss than urethane cement troweled system If aesthetics are vital & downtime not critical – best method for both is slurry/topcoat

48. Conclusions Choose the right product for the project Base your decisions on working conditions, service conditions, temperature, aesthetics Choose suppliers with a proven track record only – in similar brewing applications Choose ONLY reputable contractors, not necessarily based on lowest price Base your decision on technical documentation and not marketing hype Get a solid, clear and unambiguous warranty statement

49. Highly Decorative Flooring Epoxy Quartz with Top Coat

50. Highly Decorative – Epoxy Quartz with Top Coat

51. Highly Decorative Epoxy Quartz with Top Coat

52. Second Street Brewing – Sante Fe

54. Winery Application

55. Large Scale Winery

57. High Gloss Urethane

58. Three Floyds Brewing – Munster, IN

62. Before/After Coating

63. Slope to Drain

64. QUARTZ SAND ADDED FOR AESTHETICS

65. Brewing is in my blood…… Personal history of family involved in the brewing supplies business….

66. My Grandfather, Isaac Klapper Circa 1925 Brooklyn, New York Also known for his Bootleg “Bathtub” Gin which my Dad used to “run” Supplied many of the local home brewers in his day

67. QUESTIONS ? URETHANE CEMENTS or EPOXY COATINGS FLOORING IN A BREWERY Presented by Norm Klapper PEC – Boulder, Colorado