Chemical Processing & Petrochemical Flooring

Does a chemical plant need the same floor in every area?

No. A containment dike holding concentrated acid, a process floor taking forklift traffic and washdown, an exterior tank farm cycling through Michigan winters, and a drum warehouse with incidental leaks are four different exposure schedules, and they get four different builds. The body of the floor, the topcoat chemistry, the slope, the cove, and the joint treatment each change by zone. The zone table on this page lists starting points; the build for your plant is engineered from the substrate condition, the chemistry actually stored or processed there, and the facility’s history with previous floors.

What floor handles concentrated acid spills?

For concentrated mineral acids the starting point is a MavClad EM troweled epoxy mortar body finished with MavCoat NV, our 100% solids zero-VOC novolac epoxy, whose data sheet lists resistance to concentrated acids including 98% sulfuric acid and UAN. For dilute acids, caustics, and general plant chemistry MavCoat CRE, a chemical-resistant epoxy with superior resistance over standard epoxies, is usually sufficient. Where organic acids or hot washdown are in play, the body changes to MavCrete UM urethane cement. In every case the facility’s chemistry, concentration, temperature, and dwell time are read against the chemical-resistance chart on each product’s data sheet before the system is specified.

Do you line containment, trenches, and sumps at refineries and chemical plants?

Yes. Secondary containment dikes and curbs, trenches, sumps and pits, pump pads and pedestals, loading and unloading areas, and the process floors between them are all Maverick scope at refineries, gas processing and fractionation plants, LNG facilities, terminals, and chemical plants. The containment structure is rebuilt to sound concrete first — severe section loss and exposed rebar at curbs and pad edges are the common failure — then the cove, curb face, sump, and every penetration are detailed as one monolithic lining. Chemical exposure is assessed per facility against the chemical-resistance chart on each product’s data sheet. Process tank and vessel linings are covered on the chemical-resistant linings and secondary containment page.

Can this work be done while the plant is running?

Usually yes, zone by zone. Most chemical and petrochemical floor work is phased around live process equipment, isolated by containment area or bay, and scheduled into turnaround and outage windows. Where a fast return matters, fast-cure options exist across the line: MavCoat FC basecoat, MavRapidPatch and MavPolyPatch for repairs, and MavSeal UPA Fast Cure as a topcoat. Because Maverick formulates the products and installs them with its own crews, the sequence, cure schedule, and site safety plan come from one company under a single-source warranty.