PU concrete flooring in Ludhiana, Punjab

Ludhiana's dyeing and processing houses have some of the hardest floors in the city. Hot dye liquor spills from machines, caustic soda is used for scouring, and the floor stays wet from morning to night. Dairy and food plants around the city face a similar mix of heat, water and chemicals. For these floors, PU concrete is usually the right answer.

Dyeing and textile processing floors

Here is what typically happens to a floor in a Ludhiana dyeing house. The cement surface is eaten away by alkalis and dyes within a year or two. Aggregate shows through, then potholes form near the machines. Water and chemicals get into the potholes and start attacking the reinforcement. Epoxy coatings put down to fix it tend to lift, because the hot liquor creates thermal shock and the constant wet gets under the edges.

PU concrete behaves differently:

• It is laid 9 mm thick, so it can take hot liquor without cracking.
• It resists the alkalis used in scouring and many dyeing chemicals.
• It bonds strongly and is locked in at edges and drains with anchor grooves.
• Its textured surface stays safe to walk on when wet.

Some processes use strong acids or specialist chemicals. We ask for your chemical list at the survey. If PU concrete isn't suitable for a particular area, we will say so and suggest a chemical resistant floor for that zone.

Drain channels in processing houses

In dyeing units, the drain channel is usually the weakest part of the floor. Liquor runs along it all day, and the channel edges crumble. We rebuild channel edges, cut anchor grooves along both sides and carry the PU concrete down into the channel where the design allows it. It is the most detailed part of the job, and the part that most affects how long the floor lasts.

Dairy and food plants

Ludhiana's dairy and food units use PU concrete in milk processing areas, CIP zones, cooking and frying sections and wash rooms. Lactic acid, hot water and caustic cleaners are handled well, and the jointless coved surface helps with food safety audits.

Winter work in Punjab

Resin systems cure slowly in the cold. In Ludhiana's winter, we check slab and air temperatures before laying, close up the area and use heaters if needed. Processing houses often have warm, humid air from machines, which helps, but slabs near open doors can still be cold.

How the job is done

1. Survey, chemical list and slab assessment
2. Breakout of damaged concrete down to sound material
3. Rebuilding of potholes, channel edges and falls with suitable repair mortar
4. Anchor grooves at drains, channels, machine bases and doors
5. Coves at walls and plinths
6. PU concrete at 6 or 9 mm with anti-slip texture

We work around production by doing one machine line or bay at a time.

FAQs

Can PU concrete be laid under running dyeing machines?

The area around a machine needs to be dry and free of liquor during laying and early curing, so the machine has to be stopped for a short time. We plan it line by line so the rest of the unit keeps running.

What about areas with acid cleaning?

Tell us the acid type and strength. Many dilute acids are fine on PU concrete. Strong or hot acids may need a specialist chemical resistant system.

How soon can the dyeing line restart?

Usually within one to two days, depending on temperature. We confirm the time for each area.

Call +91-8755475716 or fill in the form below to book a site survey in Ludhiana. More details are on our PU concrete page.