Written by ICP Group

Which CastorCrete System is Right For You?

There are a lot of options to consider when selecting flooring. Narrowing it down to a liquid applied or poured in place system may lessen the options, however, not all of these systems are appropriate in food and beverage manufacturing facilities. Specifically, the use of low-cost, general-purpose resins that do not have the chemical resistance to withstand the animal fats, caustic cleaners and strong acids will cause failures.

CastorCrete offers a variety of system options, but which one is right for you?

CastorCrete polyurethane cementitious mortar systems are engineered to perform under the harshest environmental conditions providing monolithic solutions that are hygienic, durable and safe to work on.

Benefits of a CastorCrete System

There are several benefits to choosing a CastorCrete System for your facility.

  1. Industrial grade
  2. More effective for cleaning and sanitation by design
  3. Resistant to heavy load traffic
  4. Resistant to thermal shock
  5. Resistant to thermal cycling
  6. Tolerant to moisture
  7. Excellent impact resistance
  8. Resistant to salts, fats, organic acids, sanitizers and other harsh chemicals
  9. Installed in both wet and dry exposures
  10. Designed for various thicknesses
  11. Over 50 finish and color selections
  12. Quick installation eliminates downtime

Hygienic

CastorCrete mortars are industrial grade, poured in place polyurethane cement mortar systems that are monolithic and non-absorbent. This eliminates seams and cracking which allows for more effective cleaning and sanitation that is consistent with FDA, USDA and HACCP inspected facilities.

Durability

Resistant to heavy load traffic, thermal shock and thermal cycling, CastorCrete mortars are tolerant to moisture inherent in the substrate, providing excellent impact resistance. CastorCrete products by composition are resistant to salts, fats, organic acids, sanitizers and other harsh chemicals.

Safety

CastorCrete Systems can be installed to meet EHS and texture requirements in both wet and dry exposures – ensuring safe working conditions for employees, customers and visitor in any facility or space.

Design Flexibility

CastorCrete Systems can be designed to various thicknesses depending on work load and budget. These systems offer over 50 different finish and color selections utilizing our vast line of coatings options, colored vinyl flakes and decorative quartz broadcasts. Mortars cure rapidly, eliminating downtime and making for faster installations.

Typical Installations

Light & Medium Duty Systems

  • Cafeterias and break rooms
  • Restrooms and locker areas
  • Laboratory spaces
  • Corridors
  • Commercial kitchens
  • Educational facilities
  • Veterinary clinics
  • Animal holding
  • Vivariums
  • Pharmaceutical facilities

Heavy Duty Systems

  • Food & beverage production facilities
  • Chemical processing facilities
  • Heavy manufacturing
  • Water treatment plants
  • Vehicle & aircraft maintenance facilities
  • Loading docks

Which System is Right for Your Project?

CastorCrete System Selections

CastorCrete offers three base mortar options that provide the cornerstone of proper system design and selection.

Light To Heavy Load Systems

CastorCrete SL-B

This CastorCrete system is a slurry broadcast system that is offered in solid color quartz texture and sealed with a solid colored epoxy or polyurethane topcoat. Installed between 1/8″ to 1/4″ thicknesses.

CastorCrete Bio-Floor

CastorCrete Bio-Floor is a slurry mortar with a decorative flake or decorative quartz finish – typically sealed with a grout coat of epoxy and topcoat of polyurethane clear or single topcoat of polyaspartic clear and installed between 1/8″ to 1/4″ thicknesses.

CastorCrete SL-CQ

This slurry broadcast system uses decorative colored quartz in a double broadcast application. This ensures even color, texture and an increased durability. This system is sealed with a clear epoxy or polyurethane topcoat and installed between 3/16″ to 3/8″ thickness.

Medium To Heavy Load Systems

CastorCrete RT

CastorCrete RT is a gauge rake applied mortar system used as a resurfacer with a smooth finish. This system is meant for exposures up to 300F and installed between 3/16″ to 3/8″ thickness.

CastorCrete RT-B

This gauge rake applied mortar system is used as a resurfacer. CastorCrete RT-B is offered in a solid color quartz broadcast texture and sealed with a solid colored epoxy or polyurethane topcoat. Installed between 3/16″ to 3/8″ thicknesses.

CastorCrete TG

Trowel applied, this system is a heavy load resurfacer with an inherent consistent texture for exposures up to 300F. Installed between 3/16″ and 1″ thicknesses.

CastorCrete TC UV

CastorCrete TC UV is an aliphatic polyurethane cementitious topcoat loaded with aluminum oxide. This ultraviolet light resistant top coat is used over CastorCrete polyurethane cementitious mortar systems. This top coat is slip-resistant and durable. CastorCrete mortar products without a protective top coat will undergo ultraviolet light induced discoloration, but they will not degrade.

 

Still not sure which CastorCrete system is best for you? Contact your local sales rep for more information.

Download the systems brochure here.

Written by ICP Group

Preventing Disastrous Failures in a Food & Beverage Facility

Selecting a flooring system is key

Selecting a floor system in a food and beverage manufacturing facility can be just as important as choosing the materials you put through your facility.   Making the wrong decision can lead to costly repairs, employee slip hazards, and even damaging food contamination recalls. The floor is key to protecting your investment by maintaining a hygienic, safe, and durable structure.  In this context, we outline the top ten failures that food and beverage facility managers, designers, and contractors can make when selecting and installing the floor.

For more information on how to properly prepare concrete substrates, download APF’s whitepaper on surface preparation here

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Written by ICP Group

MasterWorks: Historic Colors of America

Making History Both Right and Reality

Author: Cole Stanton

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In this installment from MasterWorks, let’s explore another unique strength of ICP at the crossroads of color, design, architecture and history:  our Historic Colors of America and 20th Century Colors of America systems.  Combined, these two palettes offer the most comprehensive and accurate system for historic colors used across almost three and a half centuries of our built environment in North America.  In the future we will report on the 20th Century colors.  For this edition, the focus is on the colors from the 1600s up to the advent of the 1900s which are found in our Historic Colors of America.

 

For preservation of historic and heritage buildings, the value of these tools is self-evident.  Increasingly, a wide range of owners, managers, contractors and designers are also discovering this resource unique to ICP for remodeling and restoring irreplaceable properties.  Presently, far more of our color requests from architects and designers are for samples from the historic collections than any other system, and this growth is accelerating.  In part this is due to greater awareness as more structural professionals join the ICP MasterWorks Community.  It is also trending up because ICP users are adapting our historic colors not just for California Paint, but as well for new brands such as APF, ScuffmasterPli-Dek and Fiberlock.

For example, APF is well suited to doing custom colors and color matching as they make their own colorants and have a color lab on site. Adding a historic palette to their resources augmented an already strong skillset with custom matching. In Eagan, MN, the Scuffmaster team also welcomes the opportunities afforded by customers with historic special color needs; Scuffmaster will match any color for you with no upcharge and no minimums required.

Note one caveat is that Scuffmaster’s metallic products (Solid Metal and EnviroMetal) cannot match bright whites. The metallics start out as a straight silver – we can tip the color from there but we cannot lighten it. For a Historic Color in a sparkling or glistening Scuffmaster product, check out Scuffmaster’s finish Smooth Pearl.

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Fiberlock’s ability to match these Historic Colors is especially important for the lead paint encapsulated with LBC Lead Barrier Compound. The benefit of getting a historically accurate color and compliance with the lead laws simultaneously is extremely attractive to both architects and owners.The Las Vegas Academy High School encountered just this while needing repainting and discovering that it contained both asbestos and lead based paint. After over 70 years of exterior paint jobs, they wanted to get back to authentic color and make the architectural detail a prevalent feature once again. Check out the case study, here.

 

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Starting With a Historic New England Partnership

I grew up in Boston, and like many was spoiled by the rich history including an architectural legacy bestowed cumulatively since the 1600s.  And like many of us, I was fooled early by the dignified shades adorning the Georgians, Federals and Victorians in the cities, leafy suburbs, and bucolic farms of New England.  Snow white muntins and mullions of double-hung wood windows were an expectation.  I thought fair and quiet body colors accentuated by contrasting and conservative dark trim was status quo, but it turns out that was stereotype.  From those 1600s saltboxes through the post-moderns of the 1970s, there has been a liberal use of color, and in some eras (e.g., like the Victorian) a rollicking spectrum of paints used inside and out.  What did the colors of the past actually look like? Turns out that for many years historians mistakenly assumed that the colors of the past were somber and muted, based on colors found when modern paints were scraped away from old surfaces. However, modern scientific paint research has gradually discovered a vivid palette and surprisingly flamboyant combinations.

Pre-1939 Homes

The advancement of accuracy and accessibility of historic color took a quantum leap forward with the development of the Historic Colors of America as a joint venture of California Paints and Historic New England –  the oldest and largest regional heritage organization in the nation.   Founded in 1910, as the Society for the Preservation of New England Antiquities (SPNEA), there could be no better partner to collaborate with in search of truly authentic hues.  In conjunction with their conservators, curators, and historic architects, a team assembled by our California paint organization over several years analyzed thousands of historic colors to accurately represent the last three plus centuries.  Some colors were rediscovered from the society’s 123,000 objects and 1.5 million archival materials that chronicle life in the Northeast since the seventeenth century.  This included the singular Edward K Perry paint archive.  The Perry Paint Collection revolves around the accrued content of the client showroom (the ‘Sample Room on Newbury St.) of the Edward K. Perry Company of Boston, an important and influential design firm of the 20thcentury. This collection provides colors, as well as information about practices and materials available to the paint industry from about the 1930s to the 1980s.

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But the effort wasn’t only archival.  The collective effort was extended to the collection and analysis of hundreds of samples from real historic sites.  Historic New England leveraged their knowledge of candidate sites with probable value for research.  California Paints conducted forensic examinations to descend into field samples of paint, layer by layer, to identify and isolate lost colors and establish their provenance for now and preserve it for the future. Sometimes samples came not from buildings but from contents from folk carvings to elegant corner cupboards. These objects supplemented the research on interior colors which in past eras featured bold colors in homes.  The combination of brilliant woodwork colors and vibrant walls brought rooms alive.

 

Turning Research Into an Unprecedented Tool

The Historic Colors of America is organized by architectural era.  Some of the earliest pigments, in relatively humble hues like Farmhouse Ochre and Codman Claret, are included in the Colonial  section that houses the mid-1600s to about 1780.  Colonial architecture in this context can be thought of as structures based on the traditions and preferences that European settlers knew from their ancestral cultures and tastes.  Original Colonial styles were built primarily along the east coast (dominated by the the classicism of Georgian England), gulf coast (think St. Augustine and Spanish florida) and portions of the southwest with the renowned Mission and Spanish Baroque traditions. They were built before the era of industrialization, and unaltered examples have a characteristic “handmade” quality in such details as doors, windows, brickwork or siding. The most characteristic Colonial house is usually a one or two-story box, two rooms deep with symmetrical windows.

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The Federal style was the dominant style of the new Republic (1780-1830). During this period the population tripled in size and expanded to the west and south. The style was mostly concentrated in prosperous port cities of the eastern seaboard in Massachusetts, Rhode Island, Maine, New Hampshire, Pennsylvania, New York, South Carolina and Georgia. Diversity of spatial planning found in interiors of the period reflected the style of Robert Adam, the gifted English architect who also popularized design elements such as swags, garlands and urns. Symmetry, lightness and delicacy characterize the Federal or Adam style. One of the earliest examples of this style was the ceiling in the Mount Vernon dining room, executed for George Washington in 1775.

In general, Federal houses may be rectilinear and boxlike, with perhaps an elliptical fanlight over the front door and sidelights flanking the door. Door trim may include thin columns or pilasters and curved or octagonal projections may reveal the shape of interior rooms. Also characteristic are curving steps and windows recessed within arches. The roof is oftenconcealed  behind a balustrade.

From roughly 1825-1855, The Greek Revival period began and ended in this country with public buildings built in Philadelphia. One of the most familiar icons of American architecture is the full-colonnaded Greek Revival mansion of the southern states with its large veranda or living porch. The front-gabled house was popularized in the early nineteenth century and became the predominant form of urban houses in the northeast and Midwest well into the twentieth century.

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The classical temple form with a portico across the entire front and the roof ridge running from front to back is employed for buildings of all kinds and sizes including cottages. Dormers are rare and roofs are generally gabled or of low pitch. The front door is typically surrounded by narrow sidelights with a row of transom lights above. The most common types of ornament are the anthemion and the Greek fret, wide pilasters and deep, heavy cornices. Wooden buildings were invariably painted white.

For the balance of the 19thcentury, the styles that were popular during the long reign of Britain’s Queen Victoria are generally referred to as “Victorian.” Growth of railroads and industrialization led to changes in mass productions and shipping of house components, while the development of mechanized saws and lathes led to a profusion of wooden ornamentation. The extravagant use of complex shapes and elaborate detailing are clearly reflected in these landmark houses.

Late Victorian styles of this period, also known as “Stick” and “Queen Ann,” became intertwined and tend to overlap each other. Characteristics such as multicolored walls, asymmetrical facades, and steeply pitched roofs are common features. Dwellings were built with every conceivable type of trim including wooden lacework, patterned shingles, porches and towers with conical roofs. Roofs are often complex with cross gables, conical turrets, dormers and decorative brackets beneath eaves. Finials and crestings were frequently used to decorate the roof ridges.

 

Accessing These Color Tools

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To start browsing the historic selections, you can certainly visit a California Paint retailer that participates in this program. But ICP has made it convenient to get started online.  Several of our color systems can be explored via our Digital Fan Deck available at https://www.californiapaints.com/find-my-color/.  Select the drop down menu, and choose either Historic or 20thCentury.  Then find colors for the era of interest.  For example, if the building is in the Art Deco style, there are 38 colors in the 20thCentury Colors of America system from that period, from Bahaus to Emerald City to Gatsby Gold to Urban Brick. Of course, colors on electronic screens are just an approximation.  Color samples on cardstock are the next step, and are made available at no charge.  To send a request, take note of the preliminary color choices, and use the Digital Fan Deck’s companion order form (seehttps://www.californiapaints.com/find-my-color/color-chip-order-form/), or email requests to specifications@masterworks.com.  Please note that some seasons the volume of requests can surge, and it can take 7-10 days before color chips are processed and sent to US and Canadian addresses.

 


Want more?

From Historic New England, Here are some resources helpful when thinking about historic paints:

Moss, Roger W., ed. Paint in America: The Colors of Historic Buildings. Preservation Press: Washington, D.C., 1994.

Nash, George., Renovating Old Houses. The Taunton Press: Newtown, 1998.

Weaver, Martin, E., Conserving Buildings: A Manual of Techniques and Materials. Preservation Press: New York, 1997.

Weeks, Kay D., and Look, David W., Preservation Briefs #10, “Exterior Paint Problems on Historic Woodwork.” National Preservation Services, National Park Service: Washington, D.C., 1982.


We would love to hear from you about experiences and product needs you see across this burgeoning industry. Watch for some new LinkedIn discussion groups, and we invite you to send emails to the MasterWorks team at MasterWorks@icpgroup.com.

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