Dairy Flooring Case Study

About the Project:

• Client: Gill Dairy
• Location: South Solon, OH
• Year: 2024
• Project Scope: Repairing concrete and applying a urethane cement coating on 72 cow carousel platforms

Project Overview: Our team began by mechanically removing the previous patching material from the deteriorated concrete surfaces. After acid etching and thorough rinsing, we applied Dur-A-Flex UM Primer to all spalled areas and filled voids using Dur-A-Flex UM Mortar. Once the preparation was complete, we installed Dur-A-Flex Polycrete SL Urethane Cement (accelerated) while embedding pre-cut 10-ounce fiberglass woven mesh into the wet material, ensuring complete encapsulation. The surface was then broadcasted with silica and covered with plastic to protect it from cow interference. Finally, we applied a quarter inch of Polycrete MDB and broadcasted it with 100 grit white aluminum oxide to serve as the top coat.

Unique Aspects: To avoid disrupting farm production, the project was executed over four non-consecutive weeks, allowing us to complete 18 platforms per week while maintaining operational continuity.

Unique Challenges:

• Cows: Working around the cows, which were not accustomed to the increased activity around the carousel platforms, required careful planning and execution.
• Timeline: The nonconsecutive scheduling demanded strategic planning to eliminate production losses, ensuring the project was completed on time and within budget.

Outcome: CertaPro Painters successfully repaired and coated all 72 cow carousel platforms, delivering a robust, long-lasting finish that met the client’s stringent requirements. The project was completed on schedule and on budget, resulting in a highly satisfied customer—and a few indignant cows along the way.