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Case Study Details

Aging Warehouse Floors Transformed for Gluten-Free Food Processing Plant

Black Bear’s experience providing timely solutions for food and beverage manufacturing spaces were well suited to provide the preferred end result.

Project Overview
GF Solutions reached out to Black Bear to value engineer a solution that would salvage the existing sorting areas’ flooring and to bring it up to code. Black Bear’s experience providing timely solutions for food and beverage manufacturing spaces were well suited to provide the preferred end result. The team assessed the space, repaired the existing substrate, and provided a slip-resistant, durable floor that was easier to maintain and would support the production facility.
The Process
  • STEP 1
    Moisture testing of entire space
  • STEP 2
    Diamond grind and shot blast existing floors
  • STEP 3
    Pitch the floors to accommodate the drains
  • STEP 4
    Dur-a-Guard 50/50 (12ml DFT)
  • STEP 5
    Add 56 Grip Aluminum Oxide for slip resistance
  • STEP 6
    Apply Armor Top Satin at 2 or 4 inches
Project Details
  • Project Name - GF Solutions: Sorting Areas
  • Type of Business - Food and Beverage Manufacturing
  • Location - Methuen, Massachusetts
  • Size - 11,000 sqft
  • Products - Dur-a-Guard 50/50 with 56 grip aluminum oxide, Armor Top Satin
Challenges
Getting the flooring up to code was a priority to ensure that safety regulations were met and the required licenses would be issued. However, existing slabs were uneven and showed signs of 12 inch over 8 inch slabs. Stabilization of the large space was a challenge in an already tight timeframe. The amount of trenching involved meant that the crew needed to work on multiple phases of the project simultaneously to ensure the deadline was met and to keep the plant’s opening on schedule.

Black Bear's Solution

Black Bear suggested a mitigation system for the entire production space and pitched the floors to the drain to meet board of health and USDA compliance. Cementitious urethane was installed to blend with existing slabs, and aluminum oxide for slip resistance was added. HEPA filtered equipment and no VOC materials minimized contamination in preparation for the newly designed food processing facility.

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