Failed Dairy Brick Under Conveyors: Weekend SaniCrete STX Repair

Failed brick, low clearance conveyors, and one weekend shutdown to make it right

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Failed brick. A resinous coating slapped right on top of it. Low clearance conveyors. One weekend shutdown to make it right before Monday production.

The previous repair tried to coat over dairy brick instead of dealing with the real problem. The brick was failing underneath, so the coating failed with it. That is not fixing the floor. That is buying time.

Wet red coating over failing dairy brick beneath low-clearance stainless processing conveyors
Before: coated-over dairy brick under the conveyors
Broken dairy brick exposed through failed red floor coating under processing equipment
The real failure: brick breaking loose below the coating

Getting to the Root of the Failure

One of our crews tore it out the right way. They jackhammered every piece of brick and old coating, prepped down to sound concrete, re-sloped and filled with SaniBulk polymer concrete, then capped the floor with SaniCrete STX 3/8" cementitious urethane.

That is the difference between covering a symptom and repairing the system. In a washdown facility, loose brick and failed coating layers become moisture traps. If they stay in place, the next coating inherits the same failure.

Weekend Work in Low Clearance

This was over 1,000 square feet of jackhammering under conveyors you could barely fit under. Back to back 18-hour days. The crew stayed on it because Monday production was the deadline.

Jackhammer removing failed dairy brick and old coating from beneath low-clearance conveyors
Demo: jackhammering out brick in tight clearance
SaniCrete crew working beside protected dairy processing conveyors during brick removal and prep
Conveyors protected while removal and prep continued
Sound concrete substrate exposed and prepared under stainless conveyor supports before SaniBulk and STX installation
Prep: failed layers removed down to sound substrate
Prepared concrete floor under dairy processing conveyors before SaniBulk slope repair and STX topcoat
Prep detail under the conveyor frame

Finished Before Production Restarted

Finished red SaniCrete STX floor installed below stainless food processing conveyors
After: STX installed under the conveyor run
Wide view of completed red SaniCrete STX floor beneath two low-clearance dairy processing conveyor lines
After: both conveyor runs back on a seamless STX floor

Products Used

  • SaniBulk polymer concrete for slope correction and substrate rebuilding
  • SaniCrete STX 3/8" cementitious urethane for the finished food processing floor

Need a Floor Fixed During a Shutdown?

We handle failed brick, coating failures, slope correction, drains, cove base, and full resinous flooring systems with crews built for weekend work.

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