Industrial Floor Coating: Chocolate Shoppe Ice Cream
in Madison, WI
Location
Madison, WI
Client and Facility Overview
Chocolate Shoppe Ice Cream operates a production facility in Madison, Wisconsin, where they manufacture their specialty ice cream products. The 2,330 sq. ft. production room is a critical area of their operation, requiring specific flooring solutions to maintain proper sanitation and safety standards essential for food manufacturing.
Requested Maintenance
The client required a comprehensive flooring solution for their production room that would address multiple functional needs:
- Drainage Enhancement: Installation of new drains and proper floor pitching to improve water management
- Surface Durability: Application of a specialized urethane cement floor coating system to withstand production environment demands
- Safety Compliance: Implementation of a food-grade flooring system meeting industry standards
- Perimeter Protection: Installation of 216 linear feet of canted base around the room's perimeter
The scope included a complete floor preparation and multi-layer coating system, featuring:
- Diamond grinding and shot blasting of existing surfaces
- Application of Polycrete TF Cementitious Urethane base coat
- Installation of Duraguard coating with flintshot broadcast
- Final topcoat application of Cementitious Urethane TF Plus in Standard Red
Decision Driver and Timing
The project was driven by several critical factors:
- Construction Timeline: The work needed to coordinate with broader facility construction activities
- Operational Requirements: The production room's flooring system required upgrading to meet food manufacturing standards
- Moisture Concerns: Initial testing revealed moisture issues requiring additional primer application
- Schedule Constraints: Client established a firm 14-day completion deadline to maintain overall construction schedule
Scope of Work
The comprehensive flooring system installation included multiple phases:
Surface Preparation:
- Diamond grinding and shot blasting for optimal coating adhesion
- Polyuria patching of damaged concrete areas
- Diamond cutting and filling of control joints
- Grinding of patches and joints for surface uniformity
Base Installation:
- Installation of 3-inch canted cove base around room perimeter
- 216 linear feet of protective base coating
Coating Application:
- Base coat: Polycrete TF Cementitious Urethane applied by squeegee and back-roll
- Secondary layer: Duraguard coating with broadcast flintshot (1 lb per square foot)
- Final coat: Cementitious Urethane TF Plus topcoat in Standard Red
- Additional primer coat to address moisture concerns
Quality Control:
- Thorough cleaning between coating applications
- Removal of excess broadcast material
- Careful monitoring of coating thickness
- Implementation of proper curing conditions
Notable Details
Client Satisfaction
The project was deemed highly successful, with several key achievements:
Timeline Excellence: Completing the work four days ahead of schedule demonstrated exceptional project management and execution
Quality Delivery: The client expressed high satisfaction with both the quality of work and production efficiency
Team Performance: The crew's outstanding performance was specifically noted for their ability to exceed expectations while maintaining quality standards
Minimal Disruption: Efficient execution allowed other construction activities to proceed ahead of schedule, providing additional value to the client's overall facility improvement timeline
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