In 2018, Pro Floor Design bid on a job for a global manufacturing leader specializing in precision rubber components. The company has an impeccable reputation for precision, quality standards and practices that ensure optimum quality components meeting the most stringent of standards across aerospace, automotive, industrial, medical, and solar industries. Their facility is high volume and runs around the clock to meet demands. Design decisions in the facility must foster optimal functionality while retaining aesthetic appeal. The facility meets these needs with epoxy flooring systems – which were in need of replacement.

The company manufactures silicone products. Unfortunately, silicone is kryptonite to epoxy resin. Its highly destructive properties create a juxtaposition between the facilities needs and their production line. For safety reasons, epoxy coatings offer the most anti-slip qualities which are necessary to decrease safety hazards resulting from large amounts of slippery liquid silicone run-off. However, this safety eventually erodes as the silicone-based oils break down resinous barriers. Though the resin can withstand extreme temperatures and is resistant to most liquids and chemicals – the exception is silicone. The company repeatedly saw their flooring systems begin to break down and, eventually, fish-eye.

Secondary Problem 

These complications lead to a secondary problem: replacing floors arrests production capability. The company produces exceptionally high volumes of components 24-hours per day and each floor repair or replacement shuts down a portion of the factory, thereby compromising their production output and subsequent fulfillment. Previous installations had proven exceedingly problematic leading them to seek alternate installers.

Given their first-hand knowledge and experience with silicone’s destructive nature on their preferred flooring system, the company did their research. They sought an installer who can provide unique solutions as well as identified optimal materials. Ultimately, Pro Floor Design won the bid by working collaboratively with the client and Sherwin Williams. Applying our deep chemical engineering background, we established a 12-step solution to accommodate the unique complications of installing an epoxy floor that can withstand silicone runoff while minimizing production downtime. This process – which consisted of a tactical combination of cleanings, grindings, custom-engineered barriers and resinous coatings, and buffing – was tested and proved. Though costly, the client’s goal was not to minimize the cost of the floor but to minimize downtime.

The reason that Pro Floor Design won this bid was our engineering background. This experience allowed us to successfully troubleshoot a significant pain point for our customer by carefully engineering a solution. This same process will be applied in other areas of the facility when the production schedule allows.

 

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