As your craft brewery’s revenue increases and cash flow hits a steady stream, those farfetched dreams of brewery expansion or adding a location quickly become a reality. Here at Craft Brewing Business (CBB), we’ve covered everything your next brewery would need–from cylindroconical fermenters to automated packaging systems. Yet there is one important aspect of a brewery that is easily overlooked, even though you’re standing on top of it: Your brewery’s floor coating. Today’s coatings offer everything from heat and chemical to impact and thermal shock resistance. In short, floor coatings have you covered when it comes to safety and brewery productivity, but how do you go about selecting the best coating for your brewery?
We’re glad you asked! We caught up with Paul Koury, president of Westcoat Specialty Coating Systems, a leading innovator and manufacturer of specialty coatings for use by professionals in the design and construction industry. For more than 30 years, Westcoat has pioneered new formulas and systems specifically for waterproofing, epoxy, surface and texture coating applications. In the craft brewing industry, Westcoat has worked with the likes of Ballast Point, Knee Deep Brewing, Stone Brewing and Societe Brewing Co., to name a few. Today, Paul is going to take us through the ins and outs of selecting the proper floor coating for your craft beer operation.
CBB: Hi Paul. Thanks for taking the time to talk to us. Let’s get right into it: Why is it important for a brewery to consider a floor coating? And give us an example of a coating system that typically fits a craft brewery application.
Koury: Without an appropriate floor coating, the concrete will stain, degrade and in some cases fail. A chemical-resistant coating is a must for a craft brewery, otherwise the concrete will stain at a minimum, but more likely degrade, as the beer will eat the concrete. Floor coatings such as the Temper-Crete system help protect the concrete substrate from the harsh exposure to water and chemicals. It’s our heavy-duty, heat-resistant urethane cement for brewing, bottling and canning area floors.
CBB: Interesting. It sounds like the application is going to play a big role in determining the proper coating; so, a coating system that might be a good fit for a production brewery might not be the best solution for the restaurant side of a brewpub.
Koury: Exactly. A urethane cement coating, such as Westcoat’s Temper-Crete System, for example, is ideal for the brew facility, due to its durability, heat resistance and chemical resistance. This application also works very well in the bottling and kegging spaces due to its impact resistance. It can handle the forklifts, pallet jacks and kegs. The Temper-Crete Industrial system, on the other hand, can be applied to sloped substrates where adjacent floor drains are located.
For the restaurant side of a brewpub, some of the factors to consider are: High-heat, skid-resistance and cove applications to mention a few. Westcoat’s EC-50 Novolac is a high-heat resistant epoxy that can handle greater temperatures around oven and cooking areas. Nonskid coatings and additives are suitable when grease and other conditions are present, to keep the staff and patrons from slipping and falling. Grinding, staining and sealing the concrete with products such as our Fast Stain with a protective polyurethane sealer is one concrete restoration process for the front of the house, such as tasting or serving areas, that is highly decorative, durable and chemical-resistant. We also offer a full product line of epoxy applications that would be suitable for bathrooms, kitchens and food prep areas. Lastly, cove applications will help with meeting local codes and requirements and will aid in keeping a space clean.
CBB: Meeting codes and requirements is definitely important. What are the biggest rules that brewers need to be sure they meet in their production breweries?
Cliff hanger! Check out the answer by clicking “Next Page” Or skip it and have a floor that doesn’t meet code.
Koury: Health departments can vary by location but basically they want a non-porous and scrubbable surface to prevent bacterial growth. Federal, state and local agencies usually require floors to be easily cleanable. Also it is important to follow any OSHA or safety codes pertaining to issues such as slippage or skid resistance. Coating requirements may vary in application. For example, departments may call for a cove and trowel applied epoxy in a kitchen space. Other requirements may be USDA and VOC compliance depending on the region.
CBB: Clearly selecting a proper coating system is important, but how do you explain the return on investment to your brewery clients?
Koury: The coatings are chemical resistant and help keep the brewer from damaging the concrete, thereby saving thousands of dollars in subsequent concrete resurfacing or worse, replacement. Many breweries are located in leased spaces that ultimately have to turn the space back over. If a suitable coating wasn’t installed, there could be very costly repairs, such as resurfacing that may be needed or, in extreme cases, replacement of existing substrate. In addition, a floor coating aids to the maintenance of a facility, saving labor costs during clean up and helps maintain a sterile environment. Another superficial benefit is design and aesthetics. A floor coating such as our Acid Stain Grind & Seal System can create interest and appeal to a space and can help define an environment or brewery’s theme.
CBB: So, let’s say that the brewery has selected its coating system and is ready to hit the floor. Explain the coating process: What goes into the prep and installation?
Koury: The coating process varies depending on the desired system and existing site conditions, but preparation is crucial to the success of a coating. Diamond grind and shot blasting using dustless means are common methods for surface preparation. These methods of mechanical surface preparation vary based on the desired thickness and finish of a coating or sealer. Installation methods vary as well, depending on the desired system and application. We offer detailed system specifications, training videos and product demonstrations. We also have a Qualified Contractor Applicator or QCA program that helps connect brewers/owners with licensed and qualified applicators who are capable of installing these types of floor coatings.
CBB: How much downtime should a product brewery expect during an installation?
Koury: Could be less than a day or two and up to a few weeks, depending on the scope.
CBB: What’s the price range for floor coating installation? We know this is probably a case-by-case basis, but is there a general ballpark a brewer can expect?
Koury: Most urethane cement floors are going in for $8 to $16 per square foot; most Grind Stain and Seal processes are in the $3 to $8 per square foot range, all depending on size of job, access and process details. In most cases smaller jobs, under 1,000 square feet, would cost more. Also consider that price varies around the country and from city to city, depending on local labor rates.
Most importantly, hire a flooring contractor with expertise and ideally a local contractor with a proven reputation, and ask other brewers for referrals if you know they love their floors. It’s also wise to get backing from the product manufacturer as well as specifications to suit the need of the project.
A big CBB “Cheers!” to Paul for shining a light on coating system selection. For more info, you can head over to the Westcoat Systems website or check out the company’s blog for more brewery-specific case studies.
