Food Facility Flooring: PU Concrete, Epoxy and Hygiene

Short answer: a food plant floor has to withstand constant wet cleaning, hot water and steam, sudden temperature changes (thermal shock), organic acids such as milk, fruit and vinegar, fats, impact and the risk of slipping, all at the same time. In areas washed with hot water or steam and exposed to thermal shock and chemicals (meat, poultry and fish processing, dairies, bakeries and confectionery), polyurethane-cement PU concrete stands out. In production, packaging and storage areas at normal temperatures, a food-safe self-leveling epoxy can be used. In both cases the floor must be seamless, and wall junctions are rounded with a coving mortar.

The values below are taken from the technical data sheets of the DEMCO PUR 303 CONCRETE range and of food-safe DEMCO epoxy products.

What must a food plant floor withstand?

• Wet cleaning and hot water: the floor is washed every shift; hot water, steam and cleaning chemicals are in constant contact with the surface.
• Thermal shock: sudden temperature differences between hot-water, oven and cooking areas and cold stores cause hard, brittle coatings to crack.
• Organic acids and fats: lactic acid (dairy products), citric acid (fruit), acetic acid (vinegar), sugar, blood, animal and vegetable fats.
• Impact and traffic: pallet trucks, forklifts, dropped crates and equipment.
• Slipping: a slip-resistant surface for the safety of staff working on wet and greasy floors.
• Hygiene: an easy-to-clean, dust-free surface with no joints, cracks or corners where dirt and bacteria can collect.

What is PU concrete?

PU concrete is a hybrid floor coating that combines polyurethane resin with cement-based fillers. It is applied in thick layers, bonds strongly to concrete and withstands thermal shock much better than epoxy. The products of the DEMCO PUR 303 CONCRETE range are water-based and each takes on a different job:

Product	Role	Thickness	Slip resistance (EN 16165)	Compressive strength
DEMCO PUR 303 CONCRETE SL 20 UB/WB	Self-leveling heavy-duty floor; resists thermal shock, freeze–thaw cycles and intermittent live steam and hot-water cleaning	6 mm or more	R11	75 MPa (BS 6319-2)
DEMCO PUR 303 CONCRETE/W	Slip-resistant PU concrete for wet and dry areas; adjustable surface texture	3–5 mm	Slip-resistant surface	50.8 MPa (ASTM C109)
DEMCO PUR 303 CONCRETE SL 23 UT/WB	Hybrid system of a base coat broadcast with aggregate and a glossy, scratch-resistant topcoat	~200 µm wet film at 0.300 kg/m² per coat	R10	50 MPa (BS 6319-2)
DEMCO PUR 303 CONCRETE SL31 COVING/WB	Trowel-grade coving and surface leveling mortar; coated with SL 23 UT/WB	3–9 mm	–	54.77 MPa (ASTM C579)

The products of the range have been tested to EN 1504-2 under CE marking. Shore D hardness is ~80 for DEMCO PUR 303 CONCRETE SL 20 UB/WB and SL 23 UT/WB, and ~70 for DEMCO PUR 303 CONCRETE/W.

Which chemicals does it resist?

According to its data sheet, DEMCO PUR 303 CONCRETE SL 20 UB/WB resists spills of the following at 25 °C: 40% sodium hydroxide, saturated brine, chlorinated water, glucose syrup and sugar solution, 10% citric, tartaric and nicotinic acid, wine and beer, soft drinks, fruit juices, vegetable oil, cheese and butter, fish, shrimp and fish oil, chicken and eggs. It is also compatible with meat, fuels, hydraulic oil, coolants and detergents. It may discolor on contact with oxidizing acids.

DEMCO PUR 303 CONCRETE SL 23 UT/WB and SL31 COVING/WB resist citric acid (fruit derivatives), 50% vinegar (acetic acid), lactic acid (milk and dairy products) and alcohols (methanol, ethanol), and show high resistance to inorganic acids, fuels, mineral oils and solvents. Chemical resistance varies with contact time, temperature and cleaning; staining or discoloration may occur, but this does not affect the product's performance. For other chemicals, concentrations or service temperatures above 25 °C, consult our technical team.

When is epoxy suitable?

In areas without hot water, steam or thermal shock, where production, packaging and storage take place at normal temperatures, epoxy is an economical and hygienic solution. DEMCO EPOX 2700 SELF is a solvent-free self-leveling epoxy suitable for food contact: in overall migration tests carried out to EN 1186 it meets the legal limits set in EU 10/2011 and TGK 2019/44. Consumption is 1.6 kg/m² per 1 mm of thickness; Shore D hardness is ~76, Taber abrasion ~40 mg and compressive strength 50 N/mm². For floors and walls in areas where food is produced, stored and sold, DEMCO EPOX 145 TOP COAT is used; one coat at 0.350–0.400 kg/m² gives a dry film of 220–250 µm, and it can be applied to vertical surfaces at 400 g/m².

Epoxy is hard and does not tolerate sudden temperature changes well; where floors are washed with hot water or where hot and cold areas meet, PU concrete should be preferred. For a general comparison, see Epoxy or polyurethane?

Which system for which area?

Area	Main loads	DEMCO system
Meat, poultry and fish processing	Hot-water and steam cleaning, blood, fat, thermal shock, impact	DEMCO PUR 303 CONCRETE SL 20 UB/WB
Bakeries and confectionery	Heat, sugar, thermal shock	DEMCO PUR 303 CONCRETE SL 20 UB/WB
Milk and dairy products	Lactic acid, constant wet cleaning	DEMCO PUR 303 CONCRETE SL 23 UT/WB + SL31 COVING/WB
Beverages and fruit juice	Citric and acetic acid, sugary liquids	DEMCO PUR 303 CONCRETE SL 23 UT/WB or SL 20 UB/WB
Wet and dry production, packaging	Slipping, chemicals, mechanical load	DEMCO PUR 303 CONCRETE/W (3–5 mm)
Packaging and storage at normal temperatures	Forklift and pallet truck traffic, dry conditions	DEMCO EPOX 2700 SELF
Wall and floor junctions	Dirt and bacteria collecting in corners	Coving with DEMCO PUR 303 CONCRETE SL31 COVING/WB
Walls in food areas	Cleaning, impact	DEMCO EPOX 145 TOP COAT

The data sheet of DEMCO PUR 303 CONCRETE SL 20 UB/WB also lists freezer rooms and cold stores among its areas of use. For areas that operate at very low temperatures, define the system together with our technical team during the project.

Points to watch for a hygienic floor

• Seamless surface: the coating should be applied wall to wall in one piece, leaving no joints or cracks that can harbor bacteria.
• Coving: the wall–floor junction is rounded with DEMCO PUR 303 CONCRETE SL31 COVING/WB. 14 kg of mortar makes 4 meters of standard 75 mm coving; consumption is 1.8–2.0 kg/m² per mm.
• Slip resistance: R11 (DEMCO PUR 303 CONCRETE SL 20 UB/WB) can be chosen for wet areas and R10 (SL 23 UT/WB) for less wet areas.
• Cleaning: good cleaning extends the life of the floor considerably. DEMCO PUR 303 CONCRETE SL 20 UB/WB can be cleaned with a rotary scrubbing machine and a water-miscible cleaning agent at temperatures up to 100 °C. Regular maintenance also preserves slip resistance and color.
• Color: SL 23 UT/WB may yellow over time; the change depends on UV light and heat and is more noticeable in light colors and blue shades. This does not reduce service life or chemical resistance.
• Application conditions: DEMCO PUR 303 CONCRETE SL 20 UB/WB, SL 23 UT/WB and SL31 COVING/WB must not be used on substrates affected by rising damp or in environments with relative humidity above 75%; with SL 23 UT/WB and SL31 COVING/WB the substrate must be kept at least 3 °C above the dew point for 48 hours after application. With DEMCO PUR 303 CONCRETE/W, substrate moisture must be below 4% and ambient humidity below 65%.

How soon can the plant be back in service?

Downtime matters in food plants. The 30 °C curing values in the data sheets are:

Load	DEMCO PUR 303 CONCRETE SL 23 UT/WB	DEMCO PUR 303 CONCRETE SL31 COVING/WB
Light foot traffic	16–48 hours	8 hours
Light traffic	24 hours	24 hours
Heavy traffic	48 hours	48 hours
Full chemical resistance	7 days	7 days

These are average values and vary with site conditions. DEMCO PUR 303 CONCRETE SL 20 UB/WB and DEMCO EPOX 2700 SELF reach full cure in 7 days.

Frequently asked questions

Can epoxy flooring be used in a food plant?

Yes, in areas without hot water, steam or thermal shock. DEMCO EPOX 2700 SELF meets the EU 10/2011 and TGK 2019/44 limits in overall migration tests carried out to EN 1186. For areas washed with hot water, PU concrete is more suitable.

How thick is PU concrete applied in a food plant?

It depends on the product: DEMCO PUR 303 CONCRETE SL 20 UB/WB is applied at 6 mm or more, DEMCO PUR 303 CONCRETE/W at 3–5 mm. The coving and leveling mortar SL31 COVING/WB is used at 3–9 mm.

Does PU concrete withstand hot water and steam cleaning?

DEMCO PUR 303 CONCRETE SL 20 UB/WB was developed to withstand intermittent live steam and hot-water cleaning and is resistant to thermal shock. Regular cleaning can be done at temperatures up to 100 °C.

Is PU concrete slip-resistant?

DEMCO PUR 303 CONCRETE SL 20 UB/WB has slip resistance class R11 and SL 23 UT/WB class R10 (EN 16165). The surface texture of DEMCO PUR 303 CONCRETE/W can be adjusted.

Can PU concrete be laid without removing the existing floor?

That depends on the soundness, moisture and contamination of the existing floor; PU concrete is not applied on substrates affected by rising damp. Our technical team inspects the floor and defines the surface preparation.

Describe the areas of your plant, the cleaning method (hot water, steam, chemicals) and the traffic load in the quote form, and our technical team will recommend a system for each area. For the factors that affect cost, see the floor coating cost per square metre guide, and for all products, the flooring page.