Chemical resistant flooring in Bareilly

The Bareilly region has heavy agro-chemical industry: a large fertiliser complex in the district, sugar mills, distilleries that turn molasses into alcohol, and effluent treatment plants that come with all of them. The chemicals involved aren't always dramatic acids, but fertiliser salts, molasses, spent wash and treatment chemicals attack concrete steadily. Over a few years the result is crumbling floors, exposed reinforcement and costly structural repairs.

Fertiliser handling and storage

Fertilisers such as urea, ammonium nitrate, DAP and potash are hygroscopic. They draw moisture from the air, dissolve and form concentrated salt solutions. On bare concrete these solutions soak in and crystallise, breaking up the surface. Steel reinforcement underneath corrodes. Bagging halls and bulk stores also see heavy traffic from loaders and trucks.

For these areas we look at chemical resistant epoxy or novolac screeds with enough thickness and aggregate to handle vehicle traffic. Walls are protected to the height where product is stacked or pushed against them. Expansion joints are sealed with a sealant that won't be attacked by the salts.

Sugar mills

Mill houses, boiling houses and molasses areas deal with acidic cane juice, sulphur compounds from juice clarification, lime and hot molasses. PU concrete suits the hot and wet areas with organic acids. Around sulphitation and chemical dosing points, a stronger chemical resistant lining may be needed.

Distilleries

Spent wash from molasses distilleries is hot, acidic and very corrosive. Floors, drains and channels around fermentation and distillation, as well as spent wash handling areas, need linings designed for acidic, high-temperature effluent. Vinyl ester and novolac epoxy systems are commonly used, with falls to lined drains so spills don't stand.

Labs and effluent treatment

Factory labs need splash-resistant floors under benches and in acid stores. Effluent treatment plants need chemical resistant linings on floors, channels and sometimes tank walls, chosen for the specific chemistry of the effluent.

Before we recommend a system

We ask for:

1. the chemicals and concentrations
2. temperatures of liquids reaching the floor
3. whether exposure is splash, spill or constant
4. vehicle and equipment traffic
5. cleaning methods

For unusual chemicals, we suggest a patch test.

Preparation is the hard part

Most floors in these plants are already damaged when we are called. Chemical-contaminated concrete must be broken out to sound material and neutralised before relining. Corroded reinforcement is treated and repaired. Skipping this step means the new lining gets attacked from underneath.

Timing around the season

Sugar mills and distilleries are easiest to work in during the off-season. Fertiliser stores are best done when stock is low. We plan the work so each area is fully cured before it is exposed to chemicals again.

FAQs

Can a fertiliser store floor be lined while partly full?

Yes, in sections, if stock can be moved within the store. Each section needs several days of curing before product goes back on it.

Which system is right for spent wash areas?

Usually a vinyl ester or novolac epoxy system, depending on temperature and chemistry. We confirm after reviewing your effluent data.

Will the lining protect the concrete structure too?

Yes. A sound lining stops chemicals reaching the concrete and reinforcement, which is one of its main benefits.

Call +91-8755475716 or fill in the form below with details of your chemicals. More details are on our chemical resistant flooring page.