Urethane Concrete Mortar Flooring System

Polyurethane mortar flooring system is an innovative ground system specifically developed to address the hygiene, heavy traffic resistance, moisture tolerance, and corrosion resistance requirements of the food industry. Unlike traditional epoxy flooring, urethane mortar flooring can withstand repeated steam or boiling water cleaning, whereas epoxy resin systems are unsuitable for high-temperature cleaning and are typically limited to dry environments. In many food factories where epoxy mortar systems have been installed, substantial evidence shows that epoxy surface coatings fail to meet the extreme demands of the food industry.

The urethane mortar flooring system offers a degree of flexibility, providing excellent crack bridging, superior impact resistance, enhanced mechanical wear resistance, UV stability, and chemical corrosion resistance—particularly against organic acids and high-temperature steam cleaning.

Combining the advantages of epoxy flooring and sheet materials while overcoming their limitations, polyurethane cement mortar flooring can be applied in food processing plants, beverage factories, slaughterhouses, pharmaceutical plants, fine chemical plants, public corridors, schools, offices, exhibition halls, parking lots, and art centers—any industrial or commercial setting with special requirements. These unique properties cannot be replicated by any other technology.

Advantages of Polyurethane Mortar Flooring

Polyurethane flooring can be categorized into solvent-free polyurethane coatings and solvent-based polyurethane coatings. The systems include:
Polyurethane floor coatings/ finish paint
Urethane self-leveling flooring
Urethane concrete self-leveling
Heavy-duty corrosion-resistant polyurethane concrete
Anti-slip polyurethane grit broadcast systems

The urethane mortar flooring system represents the highest-performance polyurethane flooring solution, offering unique advantages including: exceptional temperature resistance (withstanding up to 115°C at 9mm thickness and as low as -40°C), outstanding chemical resistance to oils, acids, alkalis and other corrosive substances, superior mechanical load-bearing capacity with heavy-duty wear and impact resistance, slip-resistant properties, easy cleaning and steam-cleaning capability, impermeability to water, oil and other liquids, solvent-free (VOC-free) material composition, compliance with EN 1186 standards for contamination resistance, an antibacterial seamless surface that inhibits microbial growth, and long-term durability. This comprehensive combination of properties makes it the premier choice for demanding industrial and commercial applications.

Performance Characteristics of Polyurethane Mortar Flooring:

Eco-friendly: Non-toxic, odorless, safe and reliable, certified by environmental standards
Temperature Resistance: -40°C to +120°C (withstands hot water washing and intermittent steam cleaning)

Impact Resistance: High toughness, impact-resistant, crack-free
Chemical Resistance: Resistant to acids, alkalis, various chemicals, and oil stains
Wear Resistance: Organic-inorganic composite structure, capable of withstanding long-term friction from forklifts or trailers

Slip Resistance: Unique molecular structure and customizable surface textures meet anti-slip requirements for different environments
Aesthetic Appeal: Available in glossy, matte, or flake finishes for decorative effects

Hygiene & Cleanability: Easy to clean and maintain, resistant to frequent washing, inhibits bacterial growth, comparable to stainless steel cleaning standards

Fast Curing: Walkable in 8 hours (at 20°C), vehicle-ready in 48 hours

Aging Resistance: Durable with a service life exceeding 15 years

Sanitary: Minimal joints, seamless integration to prevent dirt and bacterial accumulation, compliant with international food safety standards (HACCP certified)

Moisture Resistance: Suitable for long-term use in humid environments

Problems with Tradition Epoxy Flooring Systems

Lack of long-term chemical resistance – Prone to corrosion
Inability to withstand cleaning liquids above 60°C – Poor heat resistance
Unsuitable for steam or hot chemical sterilization – Incompatible with high-temperature media
Vulnerable to thermal shock – Cracking and delamination under rapid temperature changes
Cracking, peeling, and delamination under impact – Low impact resistance
Multiple joints trap dirt and bacteria – Difficult to sanitize
Susceptible to thermal cycling and mechanical wear – Poor abrasion resistance
Hard to remove grease and contaminants – Health hazards due to poor cleanability
Solvent-based systems risk soil contamination – Permeability issues
Vulnerable to subfloor moisture – Poor waterproofing
Long renovation periods – Extended downtime before reuse
Failure at -20°C to -40°C – Peeling, delamination, and cracking in extreme cold
Short service life – Poor long-term durability

Polyurethane mortar flooring overcomes all these limitations, making it the optimal choice for demanding industrial and commercial environments.

Urethane Mortar Floor Case

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Urethane Mortar Self-Leveling Flooring Construction Process

Step 1: Substrate Inspection and Preparation

The concrete substrate must be structurally sound, densely compacted, and uniformly level, with all strength properties rigorously tested to meet design specifications. The minimum requirement is C30-grade concrete, achieving a compressive strength exceeding 30 MPa after 28 days of curing. The surface must exhibit no defects such as dusting (loose particles), hollow spots (voids or delamination), or pitting (surface irregularities). Additionally, the concrete’s tensile strength must surpass 2 MPa to ensure proper adhesion of subsequent layers. Strict compliance with these parameters is essential for optimal performance of the polyurethane mortar self-leveling system.

The moisture content of the concrete substrate must be less than 8%.

The concrete substrate must achieve a minimum strength grade of C30.

The substrate must achieve a minimum pull-off adhesion strength of 2 MPa.

The substrate must exhibit excellent flatness with no water ponding.

Step 2: Shot Blasting (Mechanical Surface Preparation)

Concrete Surface Preparation by Shot Blasting

Grinding vs ShotBlasting Process Comparison

Step 2: Substrate Preparation (Anchor Groove Cutting)

Dry cutting of anchor grooves with a concrete saw

The anchor groove cutting depth should generally be 1.5 to 2 times the thickness of the coating/overlay material.Grinding vs ShotBlasting Process Comparison

Step 2: Substrate Preparation (Edge Treatment)

Corner Anchor Groove Cutting

Edge Grinding Treatment

Step 2: Substrate Preparation (Detail Treatment)

Doorway Anchor Groove Cutting

Anchor Groove Cutting at Thermal Transition Zones

Step 3: Application of Polyurethane Mortar Base Layer (Trowel-On)

The primer shall be applied by troweling. Normally one coat is sufficient, while two coats are required for poor substrate conditions. Simultaneously, water-based polyurethane mortar shall be used to fill surface voids, creating mechanical anchors.