System overview
A flexible, thermal-cycling polyurethane coating system installed over prepared concrete. PU coatings combine excellent chemical resistance with UV stability and impact tolerance — a step up from epoxy where wet, thermal or chemical exposure is a factor.
Widely specified for wet-process areas, plant rooms, external walkways, cold stores and any environment where an epoxy would fail on chemistry, movement or UV.
System build thickness is determined by substrate condition, intended use and specification; heavier builds are covered by our PU screed system (see Food Grade PU Screed).
Chemical resistance depends on the selected coating and exposure, and is confirmed against the manufacturer's technical documentation for the intended cleaning and wash-down regime.
Suitable environments
- Wash-down and wet-process zones
- Plant rooms and mechanical enclosures
- External walkways and covered loading
- Cold stores and chill rooms
- Chemical decant and bunded areas
Where it's not the right choice
- Areas requiring a mirror-flat decorative body coat (specify epoxy)
- Direct thermal shock exposure on a coating build (specify PU screed, subject to manufacturer technical guidance)
- Uncured or high-moisture substrates without a DPM primer
Key benefits
- UV stability suited to sunlight exposure, dependent on the specified system
- Chemical resistance depends on the selected coating and exposure
- Thermal cycling tolerance dependent on the specified resin system and manufacturer technical guidance
- Elastic — accommodates minor substrate movement
- Seamless and easy to sanitise
Slip resistance options
- Smooth sealer — light-duty aesthetic
- Fine aggregate broadcast — commercial wet zones
- Medium aggregate broadcast — wash-down floors, kitchens
- Heavy aggregate broadcast — ramps, loading, wet processes
- Slip resistance can be tailored through system and aggregate selection
Colour and finish options
- Full RAL and BS 4800 palette
- Solid-colour matt, satin and gloss finishes
- Line-marked traffic routes, bays and hazard zones
- Colour-coded process zones for process flow separation
Installation process
- Step 01
Survey and duty specification
We survey the site, identify chemical exposure, temperature range, wash-down regime and loading. The system build, slip resistance and top-coat chemistry are specified to match, using manufacturer technical guidance.
- Step 02
Mechanical preparation
Diamond grinding or shot-blasting to the profile required by the specified system, followed by HEPA-vacuum extraction. Existing failed coatings are removed back to sound substrate.
- Step 03
Priming and repairs
Moisture-tolerant epoxy or PU primer applied. Cracks and joints repaired. Coves formed at wall junctions where hygiene requires.
- Step 04
PU body coat
Two-pack polyurethane body coat is roller-applied in coats to build the specified system.
- Step 05
Aggregate broadcast (if specified)
Aluminium-oxide or silica aggregate is broadcast into the wet layer to the specified slip resistance. Excess is vacuumed once cured.
- Step 06
PU seal coat
A clear or pigmented aliphatic PU seal coat is applied over the aggregate to lock it in and deliver the final finish.
Cure times
| Foot traffic | Varies by system and site conditions |
| Wheeled traffic | Varies by system and site conditions |
| Full chemical cure | Per manufacturer technical guidance |
| Wash-down cycle | Per manufacturer technical guidance |
Maintenance guidance
- Routine wet auto-scrub with a pH-neutral or mild-alkaline cleaner
- Periodic rotary scrub with a soft-bristle brush — inspection and maintenance requirements depend on use, traffic, cleaning regime and observed wear
- Cleaning regimes, including steam clean and pressure wash, should follow the manufacturer's technical documentation for the specified system
- Re-broadcast aggregate in heavy wet zones if slip performance drops
Typical applications
- Commercial kitchens and back-of-house
- Beverage plants, breweries and dairies
- Chemical decant, bunded storage and lab support
- External walkways, covered loading and ramps
Related commercial sectors
Technical FAQs
Frequently asked questions
A coating is thinner and suits wash-down and thermal-cycling zones. A screed is a heavier build and is specified where thermal exposure, wheeled loading and steam clean are a factor — see our Food Grade PU Screed page.
For food-contact and food-production applications, the final system must be selected according to the manufacturer’s technical documentation for the intended use.
PU coatings typically cost more than equivalent epoxy specs. The premium reflects UV stability, thermal tolerance and chemical resistance, which depend on the specified system.
Yes — UV-stable PU systems can be specified for covered external walkways, loading canopies and ramps, subject to the manufacturer's technical documentation.
Cure and return-to-service times vary by system and site conditions.
PU has built-in flexibility and accommodates minor substrate movement that would crack epoxy. Structural movement joints are always mirrored in the finish.