PU Mortar·
Why PU Mortar is the Only Choice for Food Factories
Steam cleaning, forklift traffic, and HACCP compliance — standard epoxy simply cannot handle all three.
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Maintenance
How to Maintain Your Industrial Floor and Extend Its Life
Maintenance6 min readBy Circa Industrial Services
A well-installed industrial floor is a significant investment. Whether it's a PU Mortar system in a food factory, a high-build epoxy in a warehouse, or polished concrete in a logistics centre, the floor was specified and installed to last. But how long it actually lasts depends heavily on what happens after the installation crew leaves.
In our experience, the difference between a floor that lasts 5 years and one that lasts 15 is rarely the quality of the installation. More often, it comes down to cleaning practices, chemical selection, and how quickly minor damage gets addressed. This guide covers the essentials for each of the three main industrial floor systems we install.
The Principles That Apply to Every System
Before getting into system-specific advice, there are three maintenance principles that apply regardless of what type of floor you have.
First: clean up spills immediately. Every resin floor system has chemical resistance limits. Prolonged contact with acids, solvents, or concentrated cleaning agents will degrade even the most chemically resistant surface. A spill that sits for an hour does more damage than one wiped up in five minutes.
Second: use the right equipment. Abrasive scrubbing pads, steel-bristle brushes, and high-pressure water jets can damage floor surfaces that are otherwise in good condition. Auto-scrubbers with soft nylon pads are the standard for most industrial floor types.
Third: address damage early. A small crack or chip that gets filled promptly costs almost nothing to repair. Left alone, moisture and contaminants work their way in, the damage spreads, and what was a minor repair becomes a section replacement. The cost difference is significant.
Maintaining PU Mortar Floors
PU Mortar is the most chemically and thermally robust system we install, but it still benefits from a consistent maintenance routine.
Do
- Sweep or vacuum daily to remove grit and debris that can act as abrasives under forklift tyres
- Mop with a neutral pH cleaner (pH 6–8) diluted to the manufacturer's specification
- Use an auto-scrubber with a soft nylon pad for large areas — it's faster and more consistent than manual mopping
- Rinse thoroughly after using any cleaning chemical to prevent residue build-up
- Inspect the cove base (floor-wall junction) quarterly for any signs of lifting or cracking
Don't
- Don't use highly acidic or alkaline cleaners (below pH 4 or above pH 10) for routine cleaning — they will gradually degrade the surface
- Don't use solvent-based cleaners unless specifically recommended for PU Mortar — solvents can soften the binder
- Don't allow standing water to pool near drains or at the cove base for extended periods
- Don't drag heavy equipment directly across the floor — use proper material handling equipment with appropriate wheel types
Steam cleaning
PU Mortar is rated for steam cleaning up to 100°C — one of its key advantages in food production environments. Use steam cleaning as part of your regular sanitation cycle without concern. Just ensure the surface is rinsed with clean water afterwards to remove any detergent residue.
Maintaining Epoxy Floors
Epoxy floors are durable in the right environment, but they require more careful maintenance than PU Mortar — particularly around chemical selection and impact management.
Do
- Sweep daily and mop with a mild, pH-neutral cleaner — this is the single most effective maintenance habit for epoxy
- Use soft nylon pads on auto-scrubbers — avoid abrasive pads that can dull the surface finish
- Apply a compatible floor wax or sealer every 12–24 months in high-traffic areas to protect the surface layer
- Inspect annually for hairline cracks, especially near joints, doorways, and areas with heavy point loads
- Fill small chips and cracks promptly with a compatible epoxy filler before moisture ingress causes delamination
Don't
- Don't use bleach, ammonia, or citrus-based cleaners — they break down the epoxy binder over time
- Don't use steam cleaning or hot water above 60°C — epoxy softens at elevated temperatures and can delaminate
- Don't allow chemical spills (oils, solvents, acids) to sit — clean up immediately and rinse the area
- Don't use steel wool or abrasive scrubbing pads — they scratch the surface and create micro-grooves where bacteria and dirt accumulate
Maintaining Polished Concrete Floors
Polished concrete is the lowest-maintenance system of the three — there's no coating to protect or reapply. But it still needs consistent care to preserve its appearance and performance.
Do
- Dust-mop daily with a microfibre pad — this is the most important routine for polished concrete
- Wet-mop weekly with a neutral pH cleaner specifically formulated for polished concrete (avoid general-purpose floor cleaners)
- Reapply a penetrating guard coat every 1–2 years in high-traffic areas to maintain stain resistance
- Use entrance matting at all doorways to trap grit before it reaches the polished surface
- Re-polish high-traffic areas every 3–5 years if the gloss level has visibly reduced — this is a surface buff, not a full reinstallation
Don't
- Don't use acidic cleaners (vinegar, citrus, or acid-based degreasers) — they etch the concrete surface and permanently dull the finish
- Don't use wax or acrylic floor finishes — they build up on the surface, attract dirt, and require stripping
- Don't allow oil or grease spills to sit — they penetrate the concrete and are very difficult to remove once absorbed
- Don't use abrasive scrubbing pads — they scratch the polished surface and reduce gloss
A Practical Maintenance Schedule
| Frequency | PU Mortar | Epoxy | Polished Concrete |
|---|---|---|---|
| Daily | Sweep/vacuum; spot-clean spills immediately | Sweep; mop with neutral cleaner | Dust-mop with microfibre pad |
| Weekly | Auto-scrub with neutral cleaner; rinse | Auto-scrub; inspect for new chips or cracks | Wet-mop with polished concrete cleaner |
| Quarterly | Inspect cove base and drains; fill any chips | Inspect joints and high-load areas; fill cracks | Check guard coat condition; reapply if needed |
| Annually | Full inspection; report any delamination or joint failure | Apply wax/sealer to high-traffic areas; full inspection | Full inspection; assess gloss level in traffic lanes |
| Every 3–5 years | Professional inspection; re-coat worn areas if needed | Consider full recoat if surface is heavily worn | Re-buff traffic lanes to restore gloss if required |
When to Call a Professional
Routine maintenance is something your own team can handle with the right products and equipment. But some situations require professional assessment or repair.
Call a flooring contractor when you see delamination — areas where the coating has lifted away from the substrate. This is not a DIY repair; the delaminated section needs to be removed, the substrate prepared, and the system reinstated correctly, or the problem will recur.
Also call when you see cracks that are widening or recurring in the same location. A crack that keeps coming back after patching is a sign of substrate movement or a structural issue — patching it again won't solve the underlying problem.
Finally, if your floor is approaching the end of its expected service life and you're planning a replacement, get a professional assessment before committing to the same system. The facility's use may have changed, and a different specification might serve you better for the next 10–15 years.
The Bottom Line
Industrial floors are built to take punishment — but they're not maintenance-free. The facilities we see with the longest-lasting floors are almost always the ones with a consistent daily cleaning routine, the right chemical selection, and a habit of addressing small damage before it becomes large damage.
If you're unsure what products or routines are right for your specific floor system, we're happy to advise. And if your floor is already showing signs of wear or damage, we can assess it and give you an honest view of whether repair or replacement is the more cost-effective path.
Floor showing signs of wear?
We'll assess the condition and recommend the most cost-effective next step.
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