Location: Gampaha District, Sri Lanka
Client: Private Food Processing Facility
Project Type: Industrial Epoxy Flooring & Waterproofing Solutions
Services Provided: Epoxy Flooring, Waterproofing, Surface Preparation, Chemical Hardening
Project Background
The client, a leading food processing company in Gampaha District, required a high-performance flooring and waterproofing solution for their new facility. The plant’s operations involve food preparation, packaging, and storage, requiring floors that are hygienic, seamless, durable, and resistant to moisture and chemicals.
The primary objectives were:
- Seamless, dust-free floors suitable for hygiene-sensitive areas
- Chemical and moisture resistance to withstand cleaning agents and water exposure
- Durable flooring capable of handling heavy equipment, trolleys, and foot traffic
- Compliance with food safety regulations and industry standards
Thewnadee Engineering (Pvt) Ltd was commissioned to deliver a turnkey solution, combining industrial-grade epoxy flooring with effective waterproofing systems to meet operational and safety requirements.
Challenges Faced
During the initial assessment, several challenges were identified:
- High Moisture Exposure
- Floors were expected to encounter water, cleaning chemicals, and humidity, posing a risk to concrete integrity and epoxy adhesion.
- Hygiene Standards
- Food processing areas require seamless, easy-to-clean floors to prevent bacterial growth and maintain hygiene standards.
- Heavy Equipment and Traffic
- Floors needed to withstand trolleys, forklifts, and heavy machinery, requiring high abrasion and impact resistance.
- Tight Project Schedule
- Facility commissioning was on a strict timeline, necessitating efficient installation without compromising quality.
- Safety Considerations
- Floors needed anti-slip properties to ensure worker safety in wet or oily conditions.
Engineering Solution
Thewnadee Engineering implemented a comprehensive workflow integrating industrial epoxy flooring and waterproofing:
Step 1: Surface Preparation
- The concrete substrate was cleaned using industrial sweepers and pressure washers.
- Any cracks, voids, or uneven surfaces were repaired with high-strength patching compounds.
- The substrate was mechanically profiled to ensure optimal adhesion of epoxy and waterproofing layers.
Step 2: Waterproofing System Installation
- A two-layer polyurethane waterproofing membrane was applied to prevent water penetration and moisture-related damage.
- Joints and corners received additional reinforcement with waterproofing tapes and sealants.
- The system ensured long-term moisture resistance, protecting the concrete and subsequent epoxy layers.
Step 3: Industrial Epoxy Flooring Application
- A solvent-free, chemical-resistant epoxy system was applied over the waterproofed substrate.
- The epoxy provided:
- High abrasion resistance for heavy machinery and foot traffic
- Seamless, dust-free surface for hygiene compliance
- Chemical resistance against cleaning agents and operational spills
- Multiple coats ensured uniform thickness, durability, and smooth finish.
Step 4: Anti-Slip and Finishing Measures
- Anti-slip additives were integrated in wet zones and walkways to ensure worker safety.
- Quality control inspections verified adhesion, surface uniformity, and chemical resistance.
Step 5: Curing and Protection
- The epoxy floor was allowed to cure for 48–72 hours before operational use.
- Protective measures ensured no contamination or damage during curing.
Materials and Techniques Used
- Epoxy Flooring: Solvent-free, industrial-grade, chemical and abrasion resistant
- Waterproofing System: Polyurethane membrane with reinforced tapes and sealants
- Surface Profiling Tools: Mechanical grinders for optimal epoxy adhesion
- Patching Compounds: High-strength concrete repair materials
- Anti-Slip Additives: Applied in high-risk zones for safety
- Quality Control Tools: Moisture meters, adhesion testers, and visual inspections
Project Outcome
The project was completed successfully, delivering a high-performance, hygienic, and waterproof flooring solution.
Key Achievements:
- Seamless and Hygienic Floors
- Epoxy flooring provided a smooth, dust-free, and easy-to-clean surface, essential for food processing operations.
- Durability Under Heavy Loads
- Floors withstand trolleys, forklifts, and equipment, ensuring long-term operational efficiency.
- Chemical and Moisture Resistance
- Epoxy coating and polyurethane waterproofing protected the concrete from water, cleaning agents, and spills.
- Safety Enhancement
- Anti-slip zones improved worker safety in wet or oily conditions, reducing accident risk.
- Compliance with Food Safety Standards
- Floors met hygiene and regulatory requirements for food processing facilities.
- Professional Finish
- High-gloss epoxy enhanced the facility’s professional and hygienic appearance.
Client Feedback
The client expressed high satisfaction with the project, highlighting:
- The durability and seamless finish of the flooring
- Effective waterproofing preventing moisture-related issues
- Compliance with hygiene standards essential for food safety
- Professional execution and timely completion by Thewnadee Engineering
- Cost-effective solution reducing long-term maintenance and operational downtime
Conclusion
This food processing plant project demonstrates the critical importance of combining industrial epoxy flooring with waterproofing systems in hygiene-sensitive environments. By implementing:
- Surface preparation and patching for adhesion and durability
- Polyurethane waterproofing to prevent moisture penetration
- Industrial epoxy application for chemical resistance, smoothness, and durability
- Anti-slip treatments to enhance safety
Thewnadee Engineering delivered a flooring solution that balances hygiene, safety, and operational efficiency, ensuring the facility operates safely and efficiently for years to come.
Professional flooring and waterproofing solutions are essential for food processing and other hygiene-critical facilities, providing durable, low-maintenance, and safe surfaces that meet industry standards.
