Prepared & Specialty Foods · Prepared Foods
Floors for Commissaries, Central Kitchens & Prepared Food Plants
Prepared foods operations combine everything at once: kettles and fryers, raw meat and produce prep, cook-chill, assembly lines and packaging, often in one building. Grease, hot oil and constant washdown destroy quarry tile grout and epoxy. PumaCRETE urethane concrete flooring gives every room one seamless, coved floor that handles the heat, the grease and the health inspector.
248°F
Maximum service temperature
4–6 in
Integral cove base
0.6–0.9
Wet coefficient of friction
5-yr
Written warranty
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What a commercial kitchen does to a floor
Grease and fryer oil
Grease and hot oil soften coatings and make floors dangerously slick. Urethane concrete resists oils, and slip-grade texture keeps footing secure.
Kettles and tilt skillets
Steam kettles and tilt skillets dump hot product and wash water onto the floor. The system handles boiling-to-ambient thermal shock.
Failed quarry tile grout
Tile holds up, but grout lines break down under grease and washdown and harbor bacteria. Urethane concrete has no grout lines.
Raw and ready-to-eat in one building
Raw prep sits close to cooked and assembly areas. Color zoning can mark the separation on the floor.
Constant washdown
Kitchens wash down between shifts and often between products. The floor needs to slope to drain and dry quickly.
Carts and racks
Sheet pan racks, carts and pallet jacks roll constantly. The 9,500 psi system resists the wear.
Recommended system by zone
One urethane concrete system, configured for the room you’re standing in. Thickness, texture and cove are set zone by zone. Add 1/8 in for integral cove.
| Zone | Recommended system | Key exposures |
|---|---|---|
| Cook line: fryers, ranges and griddles | 401-HF, 3/8 in (thermal), slip-grade | Hot oil, grease, heat |
| Kettles and tilt skillets | 401-HF, 3/8 in (thermal) + cove | Hot spills, steam, washdown |
| Raw protein and produce prep | 401-HF, 1/4 in + cove, slip-grade | Blood, juices, sanitizers |
| Cook-chill and blast chillers | 401-HF, 1/4 in (cold cure) | Cold, condensation |
| Assembly and packaging | 401-HF, 1/4 in + cove, color-zoned | Sanitizers, cart traffic |
| Dish and pot wash | 401-HF, 3/8 in (thermal) + cove | Hot water, detergent, constant wet |
Installing around service
Overnight and weekend phasing
Kitchens are phased room by room around production. Most rooms return to service about 24 hours after the final coat.
Replacing failed tile
Failed quarry tile is removed, the slab repaired and re-sloped, and the new floor installed in the same project.
Color zoning
Raw, cook and ready-to-eat areas can each get a distinct color from the PumaCRETE color chart.
Health code and audits
- Meets FDA Food Code floor requirements: smooth, durable, easily cleanable, with coved floor-wall junctures in washdown areas
- Meets FDA current good manufacturing practice: floors that can be adequately cleaned and kept in good repair (21 CFR Part 117)
- Commissaries producing meat and poultry products: meets 9 CFR Part 416 sanitation performance standards
- OSHA-compliant slip resistance (wet coefficient of friction 0.6–0.9)
Performance data
| Property | PumaCRETE 401-HF |
|---|---|
| Compressive strength | 9,500 psi (ASTM C579) |
| Tensile strength | 1,450 psi (ASTM C307) |
| Flexural strength | 3,200 psi (ASTM C580) |
| Bond to concrete | Exceeds substrate (ASTM D7234) |
| Abrasion resistance | 0.06 g loss (ASTM C501) |
| Impact resistance | >160 in-lb (ASTM D2794) |
| Service temperature | -40°F to 248°F |
| Thermal shock | Pass, boiling-to-ambient cycles |
| Wet coefficient of friction | 0.6–0.9 (tunable) |
| Vapor pressure tolerance | Up to 25 lbs through the slab |
| Minimum install temperature | 35°F (operating coolers) |
| Standard thickness | 1/4 in (3/8 in in thermal zones) |
Standard 1/4-inch PumaCRETE 401-HF system. Full test data is on the technical data sheets.
Three ways to buy, direct from the manufacturer
Every system on this page is made by PumaCRETE and sold direct, with no distributor markup.
Buy the materials
Urethane concrete, primers, topcoats and cove kits shipped direct from the manufacturer to your plant. No distributor markup.
Buy it installed
Turnkey installation by factory-trained crews, with material and workmanship warranties from a single source.
Train your own crew
A factory-employed PumaCRETE trainer certifies your maintenance team or local contractor on your slab: prep, mixing, troweling, cove and testing.
Frequently Asked Questions
Prepared Food Plants FAQ's
Tile itself is durable, but the grout lines break down under grease, hot water and cleaning chemicals, and then harbor bacteria. Urethane concrete has no grout lines and needs no regrouting.
Yes. It's smooth, durable, non-absorbent and easily cleanable, and integral cove base provides the coved floor-wall juncture the FDA Food Code calls for in areas cleaned by water flushing. Most state and local health departments adopt the Food Code.
We use a slip-grade aggregate around fryers and cook lines. The wet coefficient of friction runs 0.6–0.9 depending on the texture specified.
Foot traffic is possible at 6 hours. Full washdown and cart traffic about 24 hours after the final coat. We phase rooms around your production schedule.
EXPERIENCE AND EXPERTISE
Ready to spec your kitchen floors?
Get a no-obligation site assessment. We review your rooms, chemistry, temperatures and production calendar, then deliver a written specification and budget within five business days.
