{"id":9701,"date":"2026-11-04T06:12:50","date_gmt":"2026-11-04T06:12:50","guid":{"rendered":"https:\/\/www.jinyupaint.com\/?p=9701"},"modified":"2026-11-04T06:12:55","modified_gmt":"2026-11-04T06:12:55","slug":"food-plant-flooring-case-study","status":"publish","type":"post","link":"https:\/\/www.jinyupaint.com\/pt\/food-plant-flooring-case-study.html","title":{"rendered":"Case Study: 72-Hour Refurbishment of a Wet Processing Floor"},"content":{"rendered":"

This food plant flooring case study describes a wet processing dairy that had one long weekend to replace a failing floor before an audit window closed, and the sequence that made it possible.<\/p>\n\n\n\n

It covers the 72 hour floor refurbishment plan, the phasing that put five zones through four nights, how the cure window was calculated rather than assumed, and the measured outcome at twelve months.<\/p>\n\n\n\n

The client is not named at their request. The figures<\/a> come from the project record, and the four mistakes at the end are included because a case study without them is an advertisement.<\/p>\n\n\n\n

The situation: a floor that had run out of time<\/h2>\n\n\n\n

The plant processes cultured dairy in two wet rooms and a filling hall, 1,650 square metres in total. The floor was a twelve-year-old cementitious urethane, laid over a power-floated slab with falls to trench drains.<\/p>\n\n\n\n

By the spring audit it had three problems. Roughly eight per cent of the area around the drains had delaminated, two coves had opened behind the wall finish, and standing water was collecting in a bay that had settled.<\/p>\n\n\n\n

None of it was a surprise to the engineering team, who had patched for three years. What changed was the audit finding: the repair history itself became the issue, because a floor patched four times in a wet room is evidence that the system is not fit for purpose.<\/p>\n\n\n\n

Two previous contractors had offered a full replacement with a two-week shutdown, which the plant had declined twice. The third option, replacing only what had failed, had already been tried and had produced the patch history that the auditor objected to.<\/p>\n\n\n\n

The plant could not stop production for a week. The only protected window was a long weekend, seventy-two hours from Friday evening, plus four nights either side for the areas that could run on reduced output.<\/p>\n\n\n\n

The constraint that shaped everything<\/h2>\n\n\n\n

A food plant flooring case study of this kind is not a compressed version of a normal programme. It is a different design problem, because every hour spent waiting for a coat to cure is an hour that has to come from somewhere else.<\/p>\n\n\n\n

Two numbers decided the plan. The first was the time from final coat to first washdown, which the system data sheet stated at eighteen hours at twenty degrees. The second was the time to full mechanical load, which was longer than the weekend.<\/p>\n\n\n\n

That second number is the one clients forget. A floor can be walked on, cleaned and inspected long before it can take a forklift turning on it, and the difference has to be written into the restart plan or it is discovered by the first pallet.<\/p>\n\n\n\n

The window therefore covered the two wet rooms only, at a build-up of six millimetres. The packing corridor was left to the following month, which nobody liked and everybody accepted.<\/p>\n\n\n\n

What changed in the build-up<\/h2>\n\n\n\n

A wet processing retrofit fails or succeeds on preparation, and this one needed more of it than the original specification allowed. The old floor had to come up in the wet rooms, not be coated over, because a delaminated system cannot carry a new one.<\/p>\n\n\n\n

Removal on a wet processing retrofit is by planing rather than breaker, which kept the dust inside a contained area and left the slab profile usable. The slab was then shot blasted, moisture tested and repaired at two low spots before the primer went down.<\/p>\n\n\n\n

The specification moved from a four-millimetre trowelled system to a six-millimetre cementitious urethane with a broadcast finish. The extra thickness was not for load; it was to give the trowel something to work with at the drains, where the original had feathered to nothing.<\/p>\n\n\n\n

Falls were corrected in the two worst bays by a pump-applied levelling mortar before the resin, which added six hours to the programme and removed the standing water permanently.<\/p>\n\n\n\n

Phasing: five zones through four nights<\/h2>\n\n\n\n

Phasing is where a fast programme is won or lost. The plan divided the works into five zones by drain catchment, so that each zone could be isolated with a barrier and cleaned down without affecting the next.<\/p>\n\n\n\n

\"Planer<\/figure>\n\n\n\n

Figure 1: Removal in the wet rooms, inside containment.<\/p>\n\n\n\n

Zones one and two, the two wet rooms, ran inside the seventy-two hours with two crews working opposite ends. Zones three to five, the filling hall and two corridors, ran on the four nights before and after.<\/p>\n\n\n\n

Table 1: The zone plan and what each window covered.<\/p>\n\n\n\n

Zone<\/th>Area<\/th>Window<\/th>Build-up<\/th><\/tr><\/thead>
1 Wet room A<\/td>420 m2<\/td>72-hour window<\/td>6 mm cementitious urethane<\/td><\/tr>
2 Wet room B<\/td>380 m2<\/td>72-hour window<\/td>6 mm cementitious urethane<\/td><\/tr>
3 Filling hall<\/td>500 m2<\/td>Two nights after<\/td>4 mm cementitious urethane<\/td><\/tr>
4 and 5 Corridors<\/td>350 m2<\/td>Two nights before<\/td>3 mm polyurethane<\/td><\/tr><\/tbody><\/table><\/figure>\n\n\n\n

The sequence matters more than the areas. Corridors went first because they were the access route, and finishing them early meant the later crews were not walking over fresh work to reach their own zone.<\/p>\n\n\n\n

Night shift: what the hours actually look like<\/h2>\n\n\n\n

A night shift on a live plant is twelve hours of work inside a nine-hour window, because the first hour is set-up and the last two are clean-down and barrier checks.<\/p>\n\n\n\n

On the night shift, the crew arrived at 20:00 after the last clean-down of the day and worked to 05:00. Production started at 06:00, which left one hour for the supervisor to inspect the barrier, the floor edge and the route before the first trolley moved.<\/p>\n\n\n\n

The night shift pattern was chosen for temperature as much as for access. A plant at rest is cooler and has less airborne dust, which matters when a broadcast finish is open for twenty minutes.<\/p>\n\n\n\n

Phasing also has a cost in supervision. Two crews alternating nights for a week is a management problem rather than a labour problem, and the second night is where attention drops. We put the most experienced supervisor on that shift, not the first.<\/p>\n\n\n\n

The cure window, calculated not assumed<\/h2>\n\n\n\n

The cure window was set from three measurements rather than from the data sheet alone: slab temperature, air temperature and the actual humidity in the room with the extraction running.<\/p>\n\n\n\n

At eighteen degrees and seventy per cent humidity, the system reached foot traffic in five hours and was ready for a cold wash at eighteen. At fourteen degrees, the same system needed twenty-six hours to the same condition.<\/p>\n\n\n\n

Table 2: Cure stages at the two temperatures recorded during the weekend.<\/p>\n\n\n\n

Stage<\/th>At 18 C<\/th>At 14 C<\/th><\/tr><\/thead>
Foot traffic<\/td>5 hours<\/td>7 hours<\/td><\/tr>
Light equipment<\/td>12 hours<\/td>16 horas<\/td><\/tr>
Cold washdown<\/td>18 hours<\/td>26 horas<\/td><\/tr>
Hot washdown and full load<\/td>72 hours<\/td>96 hours<\/td><\/tr><\/tbody><\/table><\/figure>\n\n\n\n

The room never reached eighteen degrees on the second night. The supervisor took a reading at 22:00, held the next bay, and the cure window absorbed the delay because the phasing had a night in hand. That night in hand was the single most valuable planning decision on the job.<\/p>\n\n\n\n

Before and after, in the plant’s own terms<\/h2>\n\n\n\n

In a food plant flooring case study, a comparison is only useful if it uses the measures the plant already tracks. For this client that was audit findings, cleaning time per shift and the number of unplanned repairs.<\/p>\n\n\n\n

Table 3: The three measures the plant reported, before and twelve months after.<\/p>\n\n\n\n

Measure<\/th>Before<\/th>After<\/th><\/tr><\/thead>
Floor-related audit findings<\/td>3 major, 2 minor<\/td>0 major, 1 minor<\/td><\/tr>
Cleaning time, wet rooms<\/td>2.6 hours per shift<\/td>2.2 hours per shift<\/td><\/tr>
Unplanned floor repairs, 12 months<\/td>11<\/td>1<\/td><\/tr>
Standing water in bay 4<\/td>Daily<\/td>None recorded<\/td><\/tr><\/tbody><\/table><\/figure>\n\n\n\n

In the before and after comparison, the cleaning figure is the one the plant cares about most. A seamless floor with correct falls does not remove all cleaning time, but it removes the scrubbing at the cove<\/a> and around the drains that the old floor demanded every shift.<\/p>\n\n\n\n

The single remaining finding was a sealant joint behind a wall panel, replaced under the maintenance plan in month nine. It is in this table because leaving it out would make the numbers look like a brochure.<\/p>\n\n\n\n

Measured outcome at twelve months<\/h2>\n\n\n\n

The measured outcome for this food plant flooring case study was an inspection at twelve months by the same supervisor, with the plant engineer present, using the checklist agreed at handover. Three things were checked in every zone: adhesion by tap test, cove integrity, and drainage performance under washdown.<\/p>\n\n\n\n

No delamination was found. Two coves in wet room B showed slight discolouration but no loss of bond, which was recorded and left under observation rather than repaired.<\/p>\n\n\n\n

\"Coved<\/figure>\n\n\n\n

Figure 2: The cove detail that closed the audit finding.<\/p>\n\n\n\n

The drainage check found one low spot in a corridor outside the original scope, holding a few millimetres after washdown. It was ground and re-coated in a single night, which is the advantage of a floor that can be repaired in patches.<\/p>\n\n\n\n

The plant’s audit in the following cycle recorded no major floor findings. That is the measured outcome the project was bought for, and it is the one worth quoting.<\/p>\n\n\n\n

What went wrong, and what we changed<\/h2>\n\n\n\n

Four things went wrong on this food plant flooring case study, and each one changed how we plan these jobs now. The first was a late delivery of the levelling mortar, which cost six hours on the first night and was absorbed only because the corridors had been finished early.<\/p>\n\n\n\n

The second was a barrier that failed at 03:00 in zone two, letting dust into an adjacent clean area. Nothing was contaminated, but the clean-down took ninety minutes and the lesson was to double the barrier at any opening used by people.<\/p>\n\n\n\n

The third was temperature. The room cooled faster than forecast once the extraction was switched to full, and the supervisor had to hold a bay for four hours. Portable heating is now on the equipment list for any night work between October and April.<\/p>\n\n\n\n

The fourth was documentation. The daily records were written at the end of each shift rather than during it, and two readings were reconstructed from memory. The record survived scrutiny, but only just, and it is the reason our template now has a time column for every entry.<\/p>\n\n\n\n

The client reference, and what can be shared<\/h2>\n\n\n\n

A client reference is worth more than any photograph, and it is also the part of a food plant flooring case study that a supplier cannot publish without permission. This client agreed to the figures and the sector, and asked that the name and location stay out of it.<\/p>\n\n\n\n

A client reference in food manufacturing usually comes with conditions, because a floor problem is not something a plant wants its customers reading about. It does not weaken the reference; it changes what can be quoted.<\/p>\n\n\n\n

A food plant flooring case study is a poor substitute for a call, so ask for a reference you can telephone rather than a logo on a slide. A plant that has been through a fast refurbishment will tell you more in ten minutes than a case study can in ten pages.<\/p>\n\n\n\n

Applying the sequence to another plant<\/h2>\n\n\n\n

The sequence that made this work is not specific to dairy. Any food plant flooring case study on a live site needs the same four decisions. What must be replaced rather than coated, which zones can be isolated, where the cure time comes from, and what happens if a night is lost.<\/p>\n\n\n\n

The first decision is the one most often got wrong. A wet processing retrofit done cheaply means coating over a failing system, which is cheaper this year and more expensive next. If a floor has been patched four times in a wet room, the repair history is the diagnosis.<\/p>\n\n\n\n

A 72 hour floor refurbishment plan is judged at the restart, not at the pour, and the last decision is the one that saves the programme. A plan with no float is a plan that assumes the weather, the deliveries and the crew all behave, and on a night shift at least one of them will not.<\/p>\n\n\n\n

Ask any supplier bidding for a 72 hour floor refurbishment to show you their float, in hours, and to say which zone they would sacrifice first. The answer tells you whether they have done this before.<\/p>\n\n\n\n

Frequently asked questions<\/h2>\n\n\n\n

How is 1,650 square metres completed in 72 hours?<\/h3>\n\n\n\n

Only part of it was. The two wet rooms, 800 square metres, went through the long weekend with two crews; the filling hall and corridors ran on four nights either side. Compressing every area into one window would have failed on cure time.<\/p>\n\n\n\n

Can a resin floor really be washed down after 18 hours?<\/h3>\n\n\n\n

At eighteen degrees and moderate humidity, yes, for a cold wash. Hot washdown and full mechanical load needs around 72 hours, and a plant that starts hot cleaning early will shorten the life of the surface.<\/p>\n\n\n\n

What area can one crew install per night?<\/h3>\n\n\n\n

Between 180 and 250 square metres for a trowelled system with coves, allowing for preparation, application and clean-down. Two crews on opposite ends of a room double that, but only if the barriers and access are planned for it.<\/p>\n\n\n\n

How do you keep dust out of a running plant at night?<\/h3>\n\n\n\n

Containment rather than extraction alone: sealed barriers at every opening, negative pressure inside the work area, a wheel-wash route, and a clean-down before production arrives. Double barriers at any door people use.<\/p>\n\n\n\n

What happens if the cure is slower than planned?<\/h3>\n\n\n\n

The zone is held and the programme absorbs the delay, which is why one night of float is worth more than one extra crew. Starting the next bay early is how a recovery turns into a defect.<\/p>\n\n\n\n

Is six millimetres necessary in a wet room?<\/h3>\n\n\n\n

It was here, because the original four-millimetre system had feathered to nothing at the drains. Thickness is chosen from detail and load, not from a preference, and drains are usually where the decision is made.<\/p>\n\n\n\n

Can we have a client reference?<\/h3>\n\n\n\n

The client allows the figures and the sector to be quoted, and the full record can be discussed with their permission. Their name is withheld because a floor failure is not something a food manufacturer publicises.<\/p>\n\n\n\n

Why food plants work with Kaida Paint<\/h2>\n\n\n\n

Kaida Paint supplied the cementitious urethane, primers and levelling mortar for this project, and worked with the applicator on the zone plan before the first night. We do not run the site, so our part is narrower than a case study usually implies: we get the build-up, the cure data and the delivery dates right, and we attend the first pour. If you are planning a 72 hour floor refurbishment, send the room schedule and the shutdown<\/a> dates, and the reply is a build-up and a cure timeline you can test against your own programme.<\/p>","protected":false},"excerpt":{"rendered":"

This food plant flooring case study describes a wet processing dairy that had one long […]<\/p>\n","protected":false},"author":1,"featured_media":9625,"comment_status":"open","ping_status":"open","sticky":false,"template":"","format":"standard","meta":{"om_disable_all_campaigns":false,"_monsterinsights_skip_tracking":false,"_monsterinsights_sitenote_active":false,"_monsterinsights_sitenote_note":"","_monsterinsights_sitenote_category":0,"_uf_show_specific_survey":0,"_uf_disable_surveys":false,"footnotes":""},"categories":[1],"tags":[2153,2156,2152,2155,2154],"class_list":["post-9701","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-faq","tag-72-hour-floor-refurbishment","tag-cure-window","tag-food-plant-flooring-case-study","tag-phasing","tag-wet-processing-retrofit"],"yoast_head":"\nCase Study: 72-Hour Wet Processing Floor Refurbishment<\/title>\n<meta name=\"description\" content=\"How a dairy replaced 1,650 m2 of failing wet room floor 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