At just 2-years-old, the flooring system of a 22,000-square-foot processing plant of the Royal Shrimp Company in Nicaragua was in very bad condition, primarily due to the fact that a red topping mortar was originally placed over fresh concrete.
The original approach failed quickly, so the entire floor was coated with a grey high solids epoxy. Then the floor started failing again – the epoxy coating showed very poor adhesion and the topping mortar was not bonded well to the concrete.
Next, the company decided to remove and replace about 65% of the concrete in the facility, and the remainder with the unsound red topping had to be mechanically abraded until a sound substrate was achieved.
APF was called in to find a flooring solution that was long lasting and could withstand a high degree of impact and thermal shock.
Farallon Aquaculture, S.A. (AKA Royal Shrimp Company) is a Panamanian company founded in 1993 dedicated to larval production, cultivation and marketing of shrimp. It has a labor force of more than 1,000 employees. The operation includes seven larval production centers in Panama, Mexico, Honduras, Nicaragua, Ecuador, Venezuela, and a packaging plant in the port of Vacamonte, Panama.
Royal Shrimp Company decided not to hire a specialty contractor to install the new flooring system. They wanted their own workforce to manage the installation, none of whom had any experience installing resinous flooring.
Additionally, the installation team did not have any access to modern demolition or surface preparation equipment.
To start, APF President Daniel Owen and Sales Representative Carlos Santana went to Nicaragua to personally train the Royal Shrimp workers on how to effectively install resinous flooring. Since they lacked modern equipment, APF identified workable alternatives. They used terrazzo grinders with 20-grit stones, hand chisels and metal hatchets to remove the existing epoxy. Once removed, the installation team used HD-24 from Surface Gel Tech to etch the concrete.
In order to prevent the same flooring failures that the plant had already experienced, APF chose to install the following system:
- Urethane Mortar: CastoCrete SL-B System – A medium-duty urethane slurry that is broadcast with colored quartz. It’s designed to resurface concrete and withstand physical and chemical abuse, including high impact. CastorCrete™ SL-B produces a textured surface ideal for wet environments.
- Color Quartz Broadcast: Armor-Rez CQ 600 – A chemical-resistant, 3/16-inch thick decorative epoxy color quartz flooring system that utilizes proprietary fillers for superior impact resistance when compared to standard epoxy broadcast flooring systems.
- Topcoat: Epoxy 600 – A solvent-free, high-performance resin system designed to give improved chemical resistance over standard Bisphenol A based epoxy materials. Epoxy 600 features low viscosity, good troweling characteristics, blush-free cures and good resistance to ambering for an epoxy material.