Industrial Epoxy & Urethane Cement Flooring Case Study

Curt Maberry Farms – Lynden, WA

When it comes to food processing facilities, flooring isn’t just about durability—it’s about compliance, sanitation, and long-term performance under heavy use. Curt Maberry Farms (CMF), a leading raspberry producer in Lynden, WA, needed a flooring solution that could meet strict cleanliness standards while standing up to forklifts, moisture, and cold storage conditions.

Catalyst Coatings delivered a high-performance industrial epoxy and urethane cement flooring system—on time, on budget, and built to last.

Industrial- Cold Storage Freezer- Urethane Cement - Industrial Epoxy Floor Coating- Lynden WA

Project Overview

Client: Curt Maberry Farms (CMF)
Location: Lynden, Washington
Industry: Agriculture / Food Processing
Scope: Freezer + loading dock flooring restoration and installation
Timeline: 5 working days

Key Requirements:

• Seamless floor-to-wall system for sanitation compliance

• Fast turnaround to minimize operational downtime

• Long-lasting performance under forklift traffic

• Moisture mitigation and cold storage durabilityWhat are Carbon Nanotubes?

Carbon nanotubes are cylindrical molecules made of a single layer of carbon atoms. These tiny structures possess exceptional properties regarding structural resilience and conductivity:

• High Strength: Carbon nanotubes are significantly stronger than steel.

• Excellent Conductivity: They exhibit high electrical and thermal conductivity.

• Lightweight: They are incredibly light, making them ideal for applications where weight is a concern.

• Durability: They are resistant to wear, corrosion, and chemical damage.

The Challenge

This project involved two distinct environments, each with unique challenges:

1. Bare Concrete Freezer Space

• Severe pitting from years of freeze-thaw damage

• No previous coating system

• Required a strong, moisture-resistant base

Before – Freezer Concrete:
Bare concrete freezer floor showing severe pitting from years of freeze-thaw damage.

2. Previously Coated Loading Dock

• Existing urethane cement coating with partial failure

• Moisture intrusion beneath failed areas

• High-impact stress from daily forklift traffic

• Abrupt floor transition causing premature coating wear

Additionally, urethane cement systems are a premium material—so cost-efficiency without compromising performance was a key objective.

Before –Previously Coated Loading Dock:
Urethane cement coating failing due to UV exposure, Moisture issues, Long term abuse and old age.

Our Approach

Strategic Surface Evaluation & Cost Savings

Instead of removing the entire existing coating, our team:

• Identified and selectively removed only failed areas

• Mechanically ground intact sections to create a proper surface profile for bonding

This approach significantly reduced material costs while preserving structural integrity.

Moisture Mitigation & Structural Repair

During demolition, we discovered moisture beneath failed coating areas, along with a critical design flaw—a sharp transition point where forklifts applied repeated impact.

Our solution:

• Used heaters and scheduled downtime (during a holiday break) to draw moisture out of the slab

• Applied a moisture vapor barrier epoxy primer to prevent future delamination

Custom Transition Rebuild (Craftsmanship Highlight)

To address the high-impact zone:

• Our lead technician, Ryan, created a custom urethane cement mortar mix

• Hand-troweled a ¼”–½” thick reinforced body coat

• Mechanically ground and feathered the area to create a smooth, gradual transition

Result:

• Eliminated the stress point causing coating failure

• Improved forklift operation (operators immediately noticed the difference)

• Extended the lifespan of the flooring system

Freezer Flooring Installation

For the bare concrete freezer:

1. Shot Blasting

   • Achieved a CSP 3+ profile for optimal adhesion

2. Integral Cove Base Installation

   • Install Integral cover base transition that wraps from floor to wall

3. Surface Repair & Base Coat

   • Installed a ¼” self-leveling urethane cement system

   • Filled pitting and created a durable, thermal shock-resistant base

4. Texture System

   • Broadcast sand into the base layer to ensure slip resistance and uniform texture

Final System Build

To unify both areas and ensure long-term performance:

• Applied a urethane cement topcoat with sand broadcast for consistent texture

• Finished with two coats of fast-curing polyaspartic in light grey

Benefits of the Polyaspartic Finish:

• Extremely durable under heavy traffic

• UV stable (no yellowing over time)

• Fast cure time to accelerate project completion

• Easy to clean and maintain

The Results

✔ Seamless, sanitary floor-to-wall system
✔ Moisture protected and impact-resistant surface
✔ Improved safety and forklift usability
✔ Completed in just 5 working days
✔ Delivered on time and on budget

Curt Maberry Farms now has a flooring system built to withstand the demands of food processing, cold storage, and heavy industrial traffic—with minimal maintenance required.

Why Industrial Urethane Cement Flooring?

For facilities like CMF, urethane cement is the gold standard because it offers:

• Thermal shock resistance (ideal for freezers)

• Superior impact resistance

• Moisture tolerance

• Long service life in harsh environments

When combined with epoxy primers and polyaspartic topcoats, it creates a complete system engineered for performance.d long-lasting reliability.

Need Industrial Flooring in Lynden or Northwest Washington?

Catalyst Coatings specializes in industrial epoxy flooring, urethane cement systems, and polyaspartic coatings for:

• Food processing facilities

• Agricultural operations

• Cold storage warehouses

• Manufacturing and industrial spaces

If your facility is dealing with coating failure, moisture issues, or heavy traffic wear—we can help.

👉 Contact us today at catalystcoatings.com/contact to schedule a consultation.

KRETUS can help you evaluate your requirements and select the optimal nanotube ESD flooring system for your facility. Contact one of our product specialists for more information.

Interested in upgrading your ESD floors? Catalyst Coatings offers ESD coating systems that provide superior static control and durability. We serve Bellingham the greater Whatcom County area, and other nearby counties. Call us or request a free consultation to learn how a ESD coating can protect your facility.

This blog post was written by Trent McCrerey
Owner- Catalyst Coatings LLC