Polymer floors in wine cellars

WineLand June 2013

Charl Theron

Keywords: wine cellar floors, polymer floors. Charl Theron

Forklift traffic, barrel handling and stacking, corrosive wine acids and the humid conditions in wine cellars cause continuous damage of cellar floors. Concrete floors are the most generally found floors in wine cellars. Concrete is however porous, cracks or splints easily, which causes such floors to become a source of contamination if they are not maintained properly. The potential problems of concrete floors can, however, be overcome if they are covered with a layer of polymer. Polymer floors are durable, non-porous and seamless.

The initial cleaning of floors does not comprise sanitation, but it must be executed properly to ensure that the consequent sanitation process will be effective. As a result of the properties of polymer floors, the most pathogens can be removed relatively easy and quickly with little energy and water.

Three different polymers, namely urethane, epoxy and methylmetaacrylate are available, but is actually only the two first mentioned which must be considered by cellars. Although urethane is more expensive, it has the more superior properties of the two. Both urethane and epoxy are resins which are mixed with a catalyst to harden them and they are applied directly to prepared con-crete floors. Before the floor treatment is done cellars must consider the fol-lowing aspects:

• Cost: Seeing that a variation of different products with different colours, surface treatment, strengths and durability are available it must be decided which products are used in which locations. The floor surface of tasting rooms, bottling halls and loading areas will for example differ.

• Hardening period: While urethane sets within 5-12 hours, epoxy can take twice as long. It is important to bear this in mind if tanks and barrels for example need to be moved.

• Vapour pressure tests: The preparation of an existing floor comprises hail blasting or scraping and the sealing of the cracks to ensure a firm fixing surface. Thereafter vapour pressure tests must be executed to determine the amount of water which moves through the concrete to the surface. Urethane is better for wetter floors.

• Temperature exposure: Urethane is the best at high temperatures.

• Acid resistance: Both urethane and epoxy are good, but the specifications of the supplier must be controlled.

• Strength: Urethane is the best.

Durability is the most important property of polymer floors. It can last for 25 years and besides its the hygienic advantages, long term maintenance costs of floors can be saved.

Seeing that cellars are naturally wet, it is a slippery environment, where work-ers slip or fall easily. The surface treatment of polymer floors is consequently important. Different degrees of coarseness are available and the choice will be determined by the venue.

The aesthetic properties of polymer floors also need attention, seeing that it is not only used for cellar floors, but can also be used for tasting venues, visitor routes and reception areas. It is for instance available in different colours and reflectiing surfaces. As result of the following factors polymer floors can be seen as environmental friendly:

• Sustainable areas: Polymer products can improve existing floor surfaces considerably, preventing the necessity for new constructions or facilities.

• Water utilisation: As result of the smooth and dense surfaces much less water is required to maintain sufficient hygiene.

• Energy utilisation: The reflective surface of polymer floors can save illu-mination and consequently electricity.

• Interior environment quality: Polymer products have low volatile organic compounds (VOC) liberation and also limit noise.

• Material and sources: Resinous constituents are mixed on the site and the disposal of packaging material is consequently limited.

Wine cellars differ however regarding their individual needs and various poly-mer floors with different properties are available. The choice of the right product and a trustworthy supplier are consequently important. (Pregler, 2012)

An unmaintained cellar floor. A well maintained drain and cellar floor.

An investigation at eight American wine cellars found that cellar drains and floors were the sites with the highest potential of microbiological contamination in wine cellars. Concerning equipment, the area around barrel bungs was the largest source of contamination contrary to filling machines and sanitised stainless steel tanks which showed low contamination levels. All types of spoilage, wine yeasts and bacteria can be found at these contamination sources. A cellar with the cleanest walls, tanks and workers will still have spoilage problems if the floors are dirty. The role of cellar hygiene cannot be over emphasised.