Solutions
Table of contents
- Production Areas
- Longevity
- Oven Exits
- Mixing Areas
- Forklift Routes
- Bin or Tray Wash Areas
- Chillers
- Freezers
- Cooking Areas
- Slip Resistance
- Cleanability
- Drainage
- Coves, Kerbs and Upstands
- Aesthetic
- Flexibility to area change
- Maintenance
- Priority Area Marking
- Traffic Route Marking
- Concrete Erosion
- Substrate Protection
- Taint
- Smell
- Down Time
- UV Resistance
- Warranties
Acrylicon has unique properties that can deal with the problems in your factory. Of course we are always finding new problems, but we are also always finding new solutions.
Production Areas
The flooring requirements for general production areas have changed very little over the last 30 years. When we conducted our first survey in 1977 we found that the main requirements of 95% of the companies who took part were as follows.Longevity
Most conventional floor systems rely upon a mechanical bond to the substrate surface, ultimately risking bond failure and resulting in delamination. The result can be constant and expensive repair work Acrylicon has an unbreakable chemical bond to the special primers that have penetrated the substrate. This results in a seamless surface without holes, voids or cold joints. The whole topping is truly monolithic and it is impossible to separate the individual layers that make up the system. To remove Acrylicon from a concrete surface you will break into the top zone of the concrete not delaminate it at the Bond Line.Oven Exits
Steel wheel trolleys coming out of ovens with hot wheels can present problems to all types of resin floors dependant upon how the trolleys are parked, and for how long. Acrylicon has special solutions to deal with this problem.Mixing Areas
Issues of slip resistance and hygiene are easily dealt with by Acrylicon systems. The other problem of vibration impact at mixing bowl stations, can be readily reinforced with the Industry system. This has extremely high compressive strength, and chemically bonds to the surrounding floor, leaving no physical joints or hygiene issues.Forklift Routes
These can be general or defined routes. Acrylicon systems can cope with the continual abrasion and high traffic movements in a defined route. If the forklift routes require additional slip resistance or colour coding for health, safety or production reasons this can easily be achieved at the time of installation or later should the ergonomics of the area change. This is due to Acrylicon’s ability to chemically bond to itself, even after many years. Acrylicon will also produce high tolerance routes (superflat) for those areas involving high racking.Bin or Tray Wash Areas
These areas can be extremely aggressive not only from the hot water and detergents used but also from the impact caused by falling trays. In addition manual wash areas can be even more aggressive due to the handling of the trays. Slip resistance for operatives can also be a consideration. Acrylicon systems have proved they can withstand these areas, and in cases of extreme impact damage can be easily, quickly and cost effectively repaired due to the chemical bond and short cure time without disrupting production.Chillers
Irrespective of the operating temperature Acrylicon systems can be successfully laid down to –30degrees (slab or air temperature). This enables repair work or installation to be carried out without closing down the chiller.Freezers
Acrylicon has excellent freeze/thaw resistance. Acrylicon can still be installed at temperatures below zero degrees Celsius (slab or air temperature). When cured, after only two hours, Acrylicon can cope with temperature variations between minus 30 degrees and plus 70 degrees Celsius.Cooking Areas
This must be THE most difficult area to correctly specify. Issues of heat from both water and product allied to slip resistance creates an almost impossible problem in trying to design a solution to last 10 years plus. Heat resistant tiling can be seen as a solution, but of course the joints may well prove to be the weakness. However all cooking areas are not the same, or present the same problems. In this section we are trying to deal with those that are very aggressive in terms of boiling water and product being discharged to the floor during both production routines and cleaning. Acrylicon systems will cope with hot water and product spillage provided the volume and regularity of the spillage is not great enough to heat the WHOLE floor system to above 70 degrees Celsius. This will only happen in “hot spots” and in these situations we can combine Acrylicon with heat resistant tiling. Ultimately flooring in cooking areas fail, and generally within 6 –7 years. It is then, when the unique properties of Acrylicon systems allow the floor to be refurbished very quickly and economically back to new without major disruption. In this way, Acrylicon can be used as a system to protect the substrate whilst at the same time providing all the hygiene requirement and cleanability that is mandatory in these locations. It is our view that a flooring system that can be easily, quickly and economically repaired and returned to full function without closure is one of the most important points to consider when choosing a flooring system. Acrylicon is well versed and experienced in carrying out work in these difficult locations and has many references to prove our success over the years.Slip Resistance
Slips and trips are the most common cause of major accidents at work. The costs to industry are substantial, not counting the incalculable human cost and suffering to those injured. Legal actions brought as a result of an injury can be extremely damaging to business, especially where customers are involved. Insurance only covers a small proportion of the cost, and only if the floor is deemed as suitable in the first place. Acrylicon has various surface textures available for use on its systems. The roughest Décor Plus, meets all the Health and Safety slip resistance requirements, even when contaminated with margarine and fats. Because of Acrylicon’s unique chemical bond, any texture added to the surface becomes monolithic with the floor, and provides excellent abrasion resistance. We are also able to change areas from high grip texture to smooth texture and back again, by cleaning the surface and applying the texture. This can of course be carried out in short shutdown periods or overnight, and with the 2 hour cure, can be used again straight afterwards. There will always be a trade off between slip resistance and cleanability, therefore you can choose a system that is right for your environment. Under equipment can be smooth for ease of cleaning, and where contamination and traffic is likely, we can lay heavy texture for high slip resistance. Of course if these areas change in use, Acrylicon can always change the floor surface – giving you complete flexibility.Cleanability
The Floor must be non-porous and free of pinholes, and be capable of withstanding the chemical abuse caused by spillages and cleaning. If the surface breaks down, delaminates or becomes porous the outcome can be slippery or uneven areas, with added hygiene hazards. The floor system must retain its cleanability for life, not just for the first year or two. Acrylicon is 100% solid, resin saturated acrylic. The non-porous, monolithic, impervious Acrylicon surface does not allow penetration by liquids and dirt, or the proliferation of fungi or bacteria. Acrylicon Systems are highly resistant to chemical attack, cleaning agents, liquids and foodstuffs. Chemical bonding ensures that the wearing surface remains locked into place for the life of the floor.Drainage
Acrylicon carry a full range of special flexible resins for the creation of joints at abutments to drains, gullies and channels etc. By the use of special primers, the bond to the drain edge can be assured, creating a hygienic interface.Coves, Kerbs and Upstands
For a floor to be fully hygienic it must be easy to clean with no dirt traps. To this end most floors are laid with coving. Acrylicon can lay a variety of coves, kerbs and upstands dependant on the clients needs. Because Acrylicon chemically bonds, the coves fuse to the floor giving a totally sealed joint (as opposed to “cold joints” with other resin systems) ensuring no dirt traps.Aesthetic
Creating an environment that is conducive to high productivity and which reflect corporate values and quality standards is always important. Acrylicon provides a dynamic range of colours that can be blended to meet any requirement of the designer or architect.Flexibility to area change
Few factories or production areas remain the same for long. With equipment often being moved or replaced, the general use for the area can often change; wet to dry, production to storage etc. Because Acrylicon resins chemically bond to themselves should the area change, it is easy to change the state of the surface. For instance should a storage area become production, we can add a non-slip surface by simply cleaning the existing Acrylicon surface and applying a non-slip surface on to it. This can be done quickly as well if you consider our 2 hour cure time. Also if the floor was laid with equipment in-situ, when you come to remove the equipment, we can fill the area left and the floor chemically bonds in place, leaving a seamless floor that will not delaminate.Maintenance
When a conventional resin system becomes ready for overhauling it is necessary to completely remove it from the substrate before starting again, creating disruption, noise and dust. Alternatively the existing system is abraded to create a mechanical key for the new coating, a practice that generally fails and on some systems can be highly dangerous to health. Acrylicon is a special thermo-elastic resin that ensures each layer chemically fuses to the previous one, no matter how old. It is not possible to separate the individual layers that make up the system. Allied to a cure time of just 2 hours, this ensures that maintenance work is both more economic and less disruptive than is the case with other systems.Priority Area Marking
It is often necessary to mark out certain areas within a large area for different reasons. For instance within a food factory there might be low and high risk areas. Acrylicon can be coloured in almost any way, and where the areas come together, they are not “cold joints” but are chemically bonded, ensuring that they cannot be parted and are fully sealed. This leaves a floor that is truly “seamless” even when areas are laid in different colours.Traffic Route Marking
In busy working environments it is often required that areas safe for pedestrian use are clearly marked. The traditional method of using coloured tape to mark the boundaries or laying different floors often cause problems of delamination or wear. Acrylicon can lay these areas in a different colour to the rest of the floor, without adding weak points or joints. Because Acrylicon chemically bonds to itself, where the different floors colours meet, they chemically fuse together. This will ensure that marked areas never wear out or become unclear. We can also lay slip resistant flooring in these areas alone.Concrete Erosion
Many chemicals if allowed to penetrate the floor surface will eat away or erode the concrete substrate below. It is often difficult to properly repair these areas if they are in constant use. Acrylicon have a special system that is designed to not only repair the concrete, but also cure within 2 hours. It can also be used as a quick curing underlayment to facilitate flooring that has to be carried out in short shutdown periods. All Acrylicon flooring systems chemically bond to it and thereby effectively repair and prevent future damage.Substrate Protection
When a concrete floor is showing signs of abrasive wear the surface dusts and becomes uneven, pitted and a danger to the workforce. If the existing floor is a conventional resin system the effects of heavy wear and abrasion will show in delamination with holes creating a dangerous uneven surface and allow chemicals to attack the substrate. Acrylicon has unique primers, which are designed to achieve high penetration into the substrate. Ultimately it is the strength of the bond line that produces successful floors, and the ability of the bond line to transmit loadings and thermal changes without reducing its grip that creates longevity. The compressive, abrasion, impact and flexural strengths of Acrylicon are generally far superior compared to other systems and they do not degrade as the effect of time, water and the working environment take effect. Thereby ensuring that your substrate is protected for many years, saving you money on costly substrate repairs.Taint
All reactive resins subjected to a “Sealed Box” Taint Test in an uncured state will fail the test. The most relevant test is the “Sealed Box” taint test on the cured system which on most conventional systems cannot be done for up to twenty one days. Acrylicon installations are carried out with correct extraction equipment to ensure proper ventilation. The “Sealed Box” Taint Test can be carried out on Acrylicon just 2 hours after mixing. The possibility of taint with Acrylicon is therefore only for the period of two hours after installation, and even then only if in an unventilated environment. Because of this, the control of taint risk is much easier than with conventional resin systems which have such a long “fully cured” time.Smell
It is important to remember that smell does not mean taint risk. Many resins without smell will taint products. So when we talk about smell, we mean smell – not taste. Acrylicon is a solvent free resin, and the smell is not solvent, but just an unpleasant odour – particularly to those experiencing it for the first time. It is safe and non-toxic, and presents no health hazard. The Maximum Exposure is limited to 50 parts per million in the atmosphere, however the “smell” is noticeable at 1 part per million. At the mixing point or over the floor being laid, it is generally no higher than 20 parts per million. With extraction it is possible and not a problem to stand next to Acrylicon whilst being laid, and this is proved by the many customers we have for whom we lay in the working environment without disrupting their staff or process.Down Time
Most resins must be applied in moderate temperatures and traditional resin systems can take days to fully cure. Often other commercial pressures mean that the floor is used too soon after installation, jeopardising the system, resulting in premature damage, bacterial growth and other complications. Acrylicon fully cures, even at temperatures below zero, and can be put into use within two hours of installation. This avoids costly down time and eliminates the pressures to start using the floor too soon with the resulting damage that all too often accompanies the installation of conventional systems with long cure times. Let alone the saving to the company of shutting down production for a shorter time.UV Resistance
Most new floors look good in terms of colour, but many flooring systems show the ageing effect of UV light very quickly, both fading and discolouration. Acrylicon Systems are highly resistant to the ageing and discolouration effects of UV attack, ensuring that the aesthetic qualities of the floor are guaranteed for the long term.Warranties
Material manufactures will usually only guarantee their products. Installers usually restrict their guarantee to the installation and align it with the Manufacturers guarantee. This inevitably means that there is not a full guarantee on the system. If it fails the divided responsibilities leave the client exposed, particularly where the manufacturer and installer blame each other for the problem. Most guarantees do not:
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Decor System - Case Study
Shire Foods of Warwick Ltd