Flowcrete resin flooring systems were installed at a state-of-the-art brewery in Florida to meet the needs of a demanding production environment.

PPI Epoxy Coatings in partnership with Flowcrete Americas played a critical role in the delivery of the new brewery for Florida Beer Company located in Cape Canaveral, FL.

The 60,000 sq. ft. facility features the most efficient brewing equipment and technologies including a CombiCube B brewhouse that offers a capacity of well over 90,000 barrels, tripling the number of brews per day compared to Florida Beer Company’s previous operations.

Florida Beer Company President Jim Massoni sought a suitable flooring material that would stand up to the daily demands of the new brewhouse. Unhappy with earlier proposals, he approached Flowcrete Americas, who worked with PPI Epoxy Coatings to prepare a specification calling for the use of various specialist resin flooring systems throughout the building.

Flowfresh SRQ, a slurry broadcast cementitious urethane concrete system in a custom red colour blend was proposed for the new brewery’s central production hall and bottling plant covering 12,000 sq. ft. of floor area. Flowfresh SRQ contains coloured quartz granules that create a positively textured profile to assist with slip resistance.

The phthalate-free material also contains a powerful silver ion-based antimicrobial additive, Polygiene, which limits the spread of bacteria and other harmful pathogens. The material is designed to withstand temperature swings and thermal shock up to 180°F and offers resistance to chemical and solvent spillage.

Flowcoat SF41 HCS, a non-porous, highly chemical resistant epoxy floor coating system originally designed for the aviation industry, was recommended for use in both storage and packing halls to cover an area of 20,000 sq. ft. while an additional 7,000 sq ft in a safety yellow shade was proposed for use in the brewery’s tank fermentation area.

Flowcoat SF41 HCS has a proven international track record within the industrial manufacturing and food and beverage production sectors.

The installer, PPI Epoxy Coatings faced several challenges throughout the installation process, particularly from the absence of utilities on site and windows within the brewery. They also had to work around plumbing contractors who were installing trenches during the substrate preparation phase. The substrate was also heavily contaminated by oil due to the nature of Chrysler’s previous activities at the site.

PPI employed multiple methods of surface preparation including shot blasting with Blastrac equipment, HTC planetary grinders, hand grinders, and saw cuts around the walls and drains to create a key way to anchor the floor.

PPI President James Cook explained that the entire project from substrate preparation to the installation of the final finishes took three weeks to complete, ensuring the site was returned in time for the relocation of FBC’s operations.

He added that the client was satisfied with the end result, with PPI delivering a wear resistant, easy to maintain surface that is likely to last up to 15 years; the colourful finish also provides a great platform from which to showcase the brewery to visitors.

Texas-based Flowcrete Americas, part of the global Flowcrete Group Ltd, is a manufacturer of seamless resin flooring materials, including epoxies, urethanes, and MMAs, designed to meet the specialist needs of heavy industry, manufacturing plants and various processing facilities.

PPI Epoxy Coatings, based in Orlando, FL, specialises in the installation, repair, maintenance and protection of floor surfaces.