Sika

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Sikafloor® Solutions in Latin America

No. 42.11 – November 2011 Flooring

Flooring Project Case Studies

Project Description

Ketal was originally set up 23 years ago in 1986 as a pioneering super-market in Bolivia. Ketal subsequently began to expand and today has five branches located in different areas of the City of La Paz. In 2008, Ketal established the largest and most modern hypermarket in Bolivia, with more than 8,000 m2 of floor space with a 6 m Euro investment.In August of 2009, due to increasing demand for their processed foods, construction was started on a new processed food production and distribution centre in the Llojeta area of the city. This centre has 5,700 square metres of floor space designed to centralise all of Ketal’s processed food production including: bakery, patisserie, meat processing, sausage and pasta production, fruit and vegetable processing, plus other special food preparation areas.The investment for this is in excess of 2.5 million Euros and will enable current production to be increased threefold. The plant will start operating at the end of August 2011.

Project Requirements

The most stringent hygiene standards for the food industry had to be observed in designing and building the facility, so that the plant could achieve International Business Process Management (BPM) Standards, such as HACCP (Hazard Analysis & Critical Control Point) certification, together with the implementation of ISO Quality Systems.Floor and wall corners and intersections had to be finished without right angles or corners in a half round ‘bullnose’ or coving, in order to prevent the proliferation or build-up of micro-organisms. There are also low and very low temperature chilling stations with large refrigeration units, located in each individual production area, that required special consideration to prevent future floor damage due to thermal shock.

Ketal Hypermarket, La Paz

Boliv

ia

3

Sika Solutions

The main floor has an area of 1,713 m2 and was produced with the epoxy resin based Sikafloor®-263 SL range, which ensures hygienic surfaces free from any accumulation of food residues, with an antiseptic and easily cleaned surface. The floor system varies in thickness from 1.2 mm to 1.5 mm and thicker adjacent to the chilling stations, it is built-up using Sikafloor®-161 Primer, plus Sikafloor®-263 SL in an off white (RAL 9001) colour, mixed in the correct proportions with Sika® Quartz Filler 504.

Project Participants

Owner: Ketal HypermarketsMain Contractor: Empresa Constructora Salinas Specialist Flooring and Coating Contractor: Luis Saire

Product Quantity

Sikafloor®-161 770 kg

Sikafloor®-263 SL 2.200 kg

Filler 504 2.200 kg

Project Description

Novartis was formed in 1996 through the merger of Ciba-Geigy and Sandoz, two pharmaceutical companies based in Basel, Switzerland. Novartis now has a presence in 140 countries around the world with 360 subsidiaries and around 100,000 employees. Novartis is a major manufacturer of patent and OTC medicines, high-quality generic pharmaceutical products and vaccines.In 2009 a major maintenance programme was scheduled for the Novartis chemical plant located in the City of Resende, Rio de Janeiro State – Brazil.

Project Requirements

Novartis required a complete package of electrically conductive flooring systems for a floor area of approximately 2,500 m2, including the surface preparation and application all of which was required to be completed in just 3 weeks.The conductive flooring systems had to provide: Electrically conductive surfaces; high chemical resistance; varying degrees of anti-slip properties; all with a good aesthetic finish, that is easy to clean and with low main-tenance requirements. The ability to withstand medium levels of traffic. Additionally the flooring systems had to be quick to apply due to the tight shut-down schedule.

Novartis Chemical Plant, Rio de Janeiro State

Bras

il

5

Sika Solutions

Sikafloor®-82 EpoCem® was applied to provide a moisture barrier, stabilise and level the surface over existing acid resistant ceramic tiles that were mechanically prepared, to avoid having to lift them, enabling the new floors to be completed on schedule. The surfaces were then primed with the epoxy resin based Sikafloor®-161, over the whole of the levelling mortar to seal the surface completely.The new conductive flooring system was started just 8 hours later, by applying Sikafloor®-220 W Conductive Primer and then installing all of the necessary earthing connections with the Sikafloor® Earthing Kit system. The distances between available earthing points were bridged using Sikafloor® AS-Copper Tapes.Finally Sikafloor®-390 AS, an electrostatically conductive epoxy coating, was applied as the top coating to provide the surface chemical and mechanical resistance requirements.In areas where a highly non-slip finish was required, additional selected aggregates were broadcast to excess in the first layer and then sealed with an additional coating of Sikafloor®-390 AS.

Project Participants

Owner: NovartisFlooring Contractor: ConserpisoConductivity Assessment: LPE Consultants

Product Quantity

Sikafloor®-82 EpoCem® 2700 kg

Sikafloor®-161 520 kg

Sikafloor®-220 W Conductive 270 kg

Sikafloor®-390 AS 6825 kg

Sikafloor® AS-Copper Tape 30 rolls

Sikafloor® Earthing Kit 7 kits

Project Description

Postobón is one of the leading soft drinks manufacturing companies in Colombia. It produces and packages carbonated soft drinks, fruit drinks and a range of mineral and flavoured waters. Postobón has 7 production plants, located in the main cities of Colombia.Postobón needed to increase their capacity and production resources to meet the increasing demand from the market efficiently. Therefore the company decided to upgrade and expand the No. 3 bottling line of their ‘Gaseosas Lux’ soft drinks plant located in Bogotá.Equipment to the highest specifications and using the latest technology will be installed in this new production area, to ensure that the processes are kept under strict quality control and deliver products to international food standards.

Project Requirements

The total surface area to be refurbished and upgraded was approximately 3,000 m2 and high performance epoxy resin based flooring was to be applied to approximately 2,900 m2 of existing concrete floors; many of which were already damp from past production processes.Postobón’s National Engineering Division developed the performance specifications and then invited Sika Colombia Technical Services to assist in jointly determining the best protective systems for the floors to comply with the different production and packaging area requirements.

Postobón Soft Drinks, Bogota

Colo

mbi

a

7

Sika Solutions

The proven advantages of the EpoCem® System, not only as a moisture barrier, but also as a self-levelling mortar to smooth the surface, enabled floors to be laid in less time and the surface finish to be improved substantially.The final finishes were built up and sealed with Sikafloor®-162, which resulted in a hygienic surface with high chemical resistance, good mechanical strengths and a good decorative appearance.Sika provided the contractors with technical support on site, which also enabled the materials consumption to be optimised and any difficulties inherent in complex refurbishment projects like this one to be minimised.Additional Sika Solutions used on this project included Sikadur® epoxy adhesives and Sikagrout® cement based grouting mortars for anchoring and base plate fixing of the new equipment lines, plus Sikaflex® joint sealants.

Project Participants

Owner: Gaseosas Postobón S.A Flooring Contractor: Ecosering LTDA

Product Quantity

Sikadur 32 Primer 255 kg

Sikaguard 720 EpoCem 756 kg

Sikaguard 63N rojo óxido 68 kg

Sikarod 3/8” 1998 ml

Sikaflex 15 LM SL 25 gal

Colmasolvente Epóxico 75 gal

Imprimante Epóxico rojo 12 gal

Catalizador Imprimante Epóxico 4 gal

Sikagrout 200 3360 kg

Product Quantity

Sikafloor® EpoCem Modul 1204 kg

Sikafloor®-81 Epocem 4381 kg

Sikafloor®-2430 gris 1028 kg

Sikafloor®-162 150 kg

Project Description

In 2005, Compañía de Cervezas Nacional became part of the SAB MiIIer Group of South Africa, which in Latin America also operates in Honduras, El Salvador, Colombia, Peru, and Panama. SAB Miller is the second largest global brewery by volume, with operations in over 60 countries, across 6 continents and annual production in excess of 170 million hectolitres of beer in over 170 brands.In Ecuador, Cervecería Nacional has two plants located in Quito and Guayaquil which produce a range of beers, energy drinks and bottled waters. Production capacity is in excess of 400 million litres a year, employing 1,454 people, with sales throughout Ecuador, Latin America and they also export to the United States, Spain and Italy.

Project Requirements

In order to fulfil international drinks quality standards, Cervecería Nacional has built new modern processing areas at the Pascuales Plant in Guayaquil, which were also designed to maintain the properties and characteristics of traditional Ecuadorian beer. SAB Miller demanded high performance materials for hygienic and tough floors that also allow easy cleaning and create an environment consistent with quality beer production.The bottling and packaging materials also arrive here on conveyor belts and then go on to the filling area, so must be kept totally free from contamination to prevent any adverse effects on the beer.The work had to be carried out directly on the completely new concrete floors, just 5 days after they had been poured and finished. This required a surface vapour barrier to be applied to allow early installation of a new protective epoxy flooring system.

SAB Miller Brewery ‘Cervecería Nacional’ Guayaquil

Ecua

dor

9

Sika Solutions

The early age application was achieved by installing Sikagard®-720 EpoCem as a moisture barrier layer, which could then be followed quickly by the selected Sikafloor®-261 SL epoxy systems. This were given an additional highly chemically resistant top coating with an additional sealing coat of Sikafloor®-363 Polyurethane where required.The new concrete aisles around the plant were sealed with Sikagard® Cure Hard, to reduce the rate of evaporation and harden the concrete surface to prevent dusting and increase its resistance to traffic.

Project Participants

Owner: SA Miller – Cervecería Nacional BreweryFlooring Contractor: Sikaplica

Product Quantity

Sikafloor®-261 1.100 m2

SikaGuard cure Hard 1.400 m2

Sikafloor®-21 N PurCem gris 400 m2

Project Description

This was a government investment project declared to be in the national interest, aimed at producing cheese and powdered milk products, and including a cooperative milking parlour.The stated objective was to build a plant of the latest generation, incorporating equipment with the most advanced technology to enable the dairies to supply international markets.The new plant is located in the Maldonado province of Uruguay, in the Los Ceibos region.

Project Requirements

The new facilities required a highly durable flooring system performance characteristics including: high mechanical resistance: (i.e. to lift truck and vehicular traffic with medium to heavy loading, plus impact from dropped work tools.); resistance to thermal shock: (i.e. to cleaning with hot water, or steam at temperatures of approximately 90° C); plus chemical resistance: (i.e. to lactic acid, fats and cleaning chemical in particular).The surface finish had to be hygienic and easy to clean, with a complete absence of pores or cavities where micro-organisms might collect or grow, plus it had to be non-slip for the wet process areas with greasy residues.In addition the concrete drainage channels and support plinths for the processing equipment had to be protected with the same requirements as the rest of the floor. Finally all of the products and systems used were required to have approvals for use in food production plants to International Standards.

Farolur S.A Dairies, Maldondo

Urug

uay

11

Sika Solutions

In order to meet all the above mentioned requirements, the Project Management team selected Sikafloor® PurCem, a system incor-porating Sika’s “Polyurethane-Cement” technology.Once the new concrete slab was in place, the surface was mechanically prepared to remove any cement laitance and obtain an open textured surface (equivalent to ICRI CSP 3-6). Next anchoring cuts (slots) were made in the concrete to “toe-in” the screed and uniformly distribute the mechanical and thermal stresses into the concrete. The 5 mm floor screed was produced using Sikafloor® 19 N PurCem (RAL 1001 beige coloured) – This screed is non-slip, with high resistance to chemicals and mechanical or thermal attack for high durability.The mixed product was spread evenly using Sika’s innovative ‘screed box’ technique for rapid installation. Joints between different surfaces were then sealed with Sikaflex®-1a, high-performance, polyurethane joint sealant. Project Participants

Owner: Farolur SAArchitect: Julio Cesar OrtegaFlooring Contractor: Keber S.A.

Product Quantity

Sikafloor® 19 N PurCem 570 set x 30.28 kg

Sikafloor® 29 N PurCem 216 set x 16.84 kg

Sikafloor® 10 AR PurCem 73 set x 1 kg

Sikafloor® 363 PurCem 10 set x 18 l

Project Description

The Avent-1 plant is located in at the City of Nogales, Sonora in Mexico, where it uses the process to produce feminine hygiene products including tampons; its output of 1,500,000 units is distributed throughout the world. Refurbishment and upgrading works at the AVENT-1 plant have now been on-going for some time and in different areas; the work has been scheduled in four phased stages, with a total floor area now completed of approximately 5000 m2, plus another new 5,000 m2 warehouse area which has started construction in 2011, these floors will also be protected in accordance with modern International Standards.

Project Requirements

The main requirement for this project was to refurbish and upgrade the production areas, including treating any cracks and joints in the concrete, to seal and stabilise them so that a hygienic, easily cleaned and maintenance free area could be achieved.A protective floor coating system was required featuring high durability, with low maintenance costs and which is hygienic and easy to clean; the traffic in this area is generally light, but the owners also wanted good abrasion resistance in order to have a durable system.

Philips Avent-1 Plant (Kimberly-Clark), Sonora

Mex

ico

13

Sika Solutions

Sika Mexicana was selected as the flooring systems manufacturer on this project because of previous good service and their high-durability proposals, with the ideal system to meet all of the owner’s requirements.The system ultimately selected following detailed discussions on all aspects of the requirements, was a system using a Sikafloor®-207 based primer, followed by a self-levelling system of Sikafloor®-261 at a thickness of 2.5 mm, plus a 20-micron sacrificial top coating of Sikafloor®-203 to monitor wear.In addition, the cracks in the concrete substrate were first repaired and re-bonded with low viscosity Sikadur®-35 epoxy resin, the joints were sealed after the flooring using Sikadur®-51 SL, a tough flexible floor sealant.

Project Participants

Owner: Philips Avent (Kimberly Clark)Flooring Contractor: Unidad Técnica en Supervisión S.A. de C.V.

Product Quantity

Sikafloor®-207 408 l

Sikafloor®-261 3.423 l

Sikadur® Arena Fina 4.793 l

Sikadur®-51 SL 500 kg

Sikadur®-35 30 kg

Project Description

AFISA was created in 2000 as a joint venture between Denmark’s Arla Foods with Argentina’s SanCor; Arla Foods is a cooperative of Danish and Swedish dairy producers, with more than 50 factories in 12 countries and SanCor is the largest dairy production cooperative in Argentina.The company manufactures protein concentrates derived from cheese whey to be sold in Argentina and on the international market. Their first plant was commissioned in 2002 and, based on the success of their new processes, it was decided to expand capacity by building another new plant.Construction started in 2009 and added 7,000 square metres of floor space. SanCor’s Engineering Department managed the whole project and the total investment was 45 million Euros.

Project Requirements

Hygienic floors were required that are easy to clean and that comply with European food industry standards. The floors also had to withstand the different mechanical and chemical wear and tear requirements in every sector of the new plant.Hygienic wall coatings were also necessary to ensure that all surfaces are easy to clean and these had to be based on solvent-free materials, this was to allow safe application with other trades working in the areas.

AFISA (Arla Foods Ingredients S.A.), Porteña, Córdoba

Arge

ntin

a

15

Sika Solutions

The Sika solutions for the floors consisted of the Sikafloor®-263 self-smoothing system over Sikafloor®-161 primer and screed. Sikafloor®-263 was also used as the topcoat on stair risers and the vertical sides of plinths, plus the walls were coated with Sikagard®-63. RAL 1015 (Light Ivory) colour was used for the floors and RAL 9001 (Cream) was the colour selected for the wall coating.The floor joints were primed with Sika Primer® and then sealed with Sikaflex® Pro 3 WF.In the existing milk delivery and unloading areas, where the existing flooring had worn away, the surfaces were mechanically prepared and a high performance screed was laid using Sikafloor® 31 N PurCem.Additional Sika products were also used throughout the project including Sika concrete and mortar admixtures; Sika waterproofing additives; Sikadur® epoxy adhesives; Sika polymer modified repair mortars; Sikaflex® polyurethane joint sealants and Sikasil® silicone sanitary sealants.

Project Participants

Owner: AFISA (Arla Foods Ingredients S.A.) Project Management: SanCor Engineering Dept

Sikacrete Plus Sikagrout®-212

Sika®-2 Sikafloor®-161

Sika®-3 S/Cloruro Sikafloor®-263

Sikadur®-31 Sikafloor Carga Autonivelante

Sikadur®-32 Gel Sika Thinner

Sika Anchorfix 1 Sikaguard®-63 Esmalte

Sika Monotop 615 Sikaflex Pro 3 WF

Sika Latex Sikaflex Construccion

Sikacim Sikasil C Transparente

Sika Monotop 107

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