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Project Story

Polyurethane Mortar Flooring for a 10,000 m² Seafood Processing Facility

KAIDA PAINT supplied the high-performance polyurethane mortar systems and engineered a comprehensive installation strategy for a 10,000 m² seafood processing plant in Venezuela. The project demanded exceptional resistance to saline corrosion, organic acids, and thermal shock, while maintaining the highest food-grade hygiene standards (HACCP/FDA) and anti-slip safety for high-moisture environments.

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Client Challenge

Engineering a HACCP-compliant floor for Maracaibo’s extreme seafood processing environments—from saltwater corrosion to -40°C cold storage.

Seafood processing demands a floor that survives brutal contrasts: the constant saline corrosion of processing zones and the extreme sub-zero temperatures of flash freezers. During our site assessment in Maracaibo, we tackled a 27% substrate moisture challenge and designed a system capable of handling **thermal shock**—the rapid transition between hot washdowns and cold storage. Our polyurethane mortar solution ensures structural integrity where standard epoxy fails.

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High Moisture Remediation (27% MC)

Maracaibo’s humid climate resulted in a critical 27% moisture content in the concrete. We deployed advanced moisture-reduction measures to stabilize the substrate below 10%, preventing delamination and ensuring an unbreakable chemical bond for the PU mortar system.

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Thermal Shock & Cold Storage Stability

The facility features flash freezers and cold storage units. We installed a heavy-duty PU mortar system with a thermal expansion coefficient matching concrete. This allows the floor to remain stable during extreme temperature swings (from -40°C to +80°C), preventing cracks during steam cleaning or freezer operation.

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Elite Sanitary Detailing & R12 Slip Resistance

Seafood export requires zero-bacteria "dead zones." We provided on-site technical training for workers to install seamless circular arc corners (coving). This ensures full HACCP compliance while achieving an R12 slip-resistance rating for worker safety in wet zones.

Internal view of a high-intensity shrimp processing zone in Maracaibo, showing wet floors and the need for HACCP-compliant flooring.
Internal view of a high-intensity shrimp processing zone in Maracaibo, showing wet floors and the need for HACCP-compliant flooring.
Before renovation: Standing water and drainage issues on the original floor of a seafood processing plant, creating hygiene risks.
Before renovation: Standing water and drainage issues on the original floor of a seafood processing plant, creating hygiene risks.
Industrial pallet jack operation on a wet, slippery floor near a linear drain in a Maracaibo shrimp processing facility.
Industrial pallet jack operation on a wet, slippery floor near a linear drain in a Maracaibo shrimp processing facility.
Cold room challenge: Severe ice accumulation on the industrial floor near the loading dock, creating extreme slip hazards and substrate stress.
Cold room challenge: Severe ice accumulation on the industrial floor near the loading dock, creating extreme slip hazards and substrate stress.
Industrial corridor in a seafood processing plant with visible ice on the floor, requiring specialized low-temperature polyurethane mortar.
Industrial corridor in a seafood processing plant with visible ice on the floor, requiring specialized low-temperature polyurethane mortar.
Extreme conditions: Iced-over wall-to-floor junction with visible cracks, demonstrating the need for thermal-shock resistant coving in cold storage.
Extreme conditions: Iced-over wall-to-floor junction with visible cracks, demonstrating the need for thermal-shock resistant coving in cold storage.
Recommended Solution

A robust PU Mortar system engineered for Maracaibo’s seafood processing demands.

KAIDA PAINT engineered a heavy-duty Polyurethane Mortar system featuring a specialized moisture-tolerant primer, a high-impact mortar body, and a chemical-resistant slip-proof topcoat. Our technical team provided end-to-end support: from moisture remediation training and on-site supervision to the final hygiene compliance inspection.

Moisture-Blocking Primer

A high-performance moisture-tolerant primer sealed the damp substrate, creating a powerful chemical bond that prevents delamination even in Maracaibo’s high-humidity environment.

Performance Target

100% salt and acid resistance, heavy-duty durability for industrial traffic, and a seamless, anti-slip surface that exceeds international HACCP seafood safety standards.

Professional Support

Factory-direct material supply, on-site technical training for workers (coving/arc corners), precise consumption control, and a rigorous final quality checklist.

Construction Process

From substrate remediation to final inspection, every step was planned for durability and hygiene.

Step 01

Surface Preparation

Precision diamond grinding to open the concrete pores and mechanical cutting of reinforcement joints to ensure structural stability of the system.

Step 02

Moisture Control

Implemented forced moisture reduction and dehumidification to lower the substrate moisture content from a critical 27% to a safe level below 10%.

Step 03

Coving Training

Conducted specialized on-site technical training for the local crew to master the installation of seamless circular arc corners (coving) for zero-bacteria joints.

Step 04

Primer Application

Application of a high-performance moisture-tolerant primer to seal the substrate and provide an unbreakable bond for the heavy-duty mortar layers.

Step 05

PU Mortar Layering

Screeding of the heavy-duty polyurethane mortar body, engineered for extreme chemical resistance and thermal shock durability in the shrimp processing area.

Step 06

Final Inspection

A rigorous final quality audit focusing on surface flatness, slip-resistance coefficient, and HACCP hygiene compliance for seafood export.

Industrial floor grinding and surface preparation using specialized machinery at a sea shrimp processing factory in Maracaibo, Venezuela.
Professional flooring crew performing diamond grinding and joint cutting at a large-scale shrimp factory in Venezuela.
Project Results

The high-performance PU Mortar floor delivered a durable, hygienic, and salt-resistant surface for export-grade seafood production.

KAIDA PAINT successfully completed the 10,000 m² installation, delivering a heavy-duty polyurethane mortar system designed for the rigors of shrimp processing. Our holistic approach—encompassing moisture remediation, site-specific training, and high-traction finishes—ensures the facility now meets the strictest international food safety audits while providing a safe, long-lasting workspace.

Elite Thermal Shock & Slip Resistance

Our PU mortar system withstands extreme temperature shifts (from cold storage to hot washdowns) and provides R11-level slip safety in constantly wet environments.

Full HACCP & FDA Compliance

The seamless, antimicrobial surface eliminated bacteria traps, ensuring the facility passed all hygiene audits for seafood export.

Enhanced Safety & Durability

High slip-resistance and superior bond strength ensure a safe workplace and long-term resistance to Maracaibo’s corrosive saline environment.

“By solving our critical moisture challenges and training our local team on sanitary detailing, the [Your Brand Name] team delivered a floor that exceeded our expectations for both durability and hygiene.”

Completed high-gloss blue polyurethane mortar flooring with a stainless steel linear drain in a Maracaibo seafood processing plant.
Completed high-gloss blue polyurethane mortar flooring with a stainless steel linear drain in a Maracaibo seafood processing plant.
FAQ

Questions overseas buyers usually ask before starting a similar floor project.

This case library helps international clients confirm our expertise in delivering high-performance floors for challenging food-processing environments.

    • Seafood plants involve constant exposure to salt water, organic acids, and thermal shock from hot washdowns. PU Mortar has a thermal expansion coefficient similar to concrete, preventing delamination under temperature shifts, and offers superior chemical resistance that standard epoxy cannot match.

We use specialized moisture-tolerant primers and remediation protocols to stabilize the substrate. In the Maracaibo project, we successfully managed a 27% moisture level by reducing it to a safe threshold before application, ensuring a permanent chemical bond.

Yes. Our PU Mortar systems are seamless, antimicrobial, and non-porous. They are specifically designed to meet HACCP, FDA, and USDA requirements, ensuring zero bacteria traps and easy sanitization for export-grade facilities.

Absolutely. We provide comprehensive technical support, including project-specific Method Statements and on-site supervisor guidance. For the Venezuela project, we successfully trained local crews to master precision detailing like sanitary coving (arc corners).

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