Mining, Metals & Heavy Industry Flooring Systems
Steel mills, foundries, stamping plants, plating and pickling lines, ore and mineral processing plants, shipyards, and ports. Maverick engineers the floors that take dropped steel, abrasive fines, coolant, and acid, and the tank linings and secondary containment that hold the chemistry — one zone at a time, built to what each zone actually sees.
Heavy Industry Is Not One Floor
A foundry shakeout floor, a CNC cell, a pickling line, and a reagent storage room are four different problems in the same plant. Impact, abrasion, chemistry, heat cycling, and traffic each pull the build in a different direction, so we match the body, the topcoat, and the detailing to each zone instead of specifying one system plant-wide.
Most heavy-industrial floors start with a ¼″ troweled mortar body — MavClad EM epoxy mortar where impact and hard wheels dominate, MavCrete UM urethane cement where heat cycling and washdown are in play. Chemical zones add a MavCoat NV novolac topcoat, lined trenches and sumps, secondary containment, and tank and process immersion linings for plating, pickling, galvanizing, and leaching service, with the resin selected against the chemical-resistance chart on each product data sheet and the exposure assessed for your facility. Resinous floors serve the areas around hot-metal handling, not the surfaces that take molten metal.
Foundry & Casting Floors
Shakeout, cooling, and finishing areas where castings drop, sand abrades, and heat cycles through the slab. Resinous floors serve the work around the pour line, never the molten-metal surfaces themselves.
Machining & CNC
Coolant, cutting oil, and chips make a slick, stained floor. We build a sealed, slip-resistant surface that cleans up and takes the tool carts, pallet jacks, and machine moves of a working cell.
Plating, Pickling & Galvanizing Lines
Acid and caustic baths, rinse water, and fume condensate attack concrete fast. The floor is a troweled mortar body under a MavCoat NV novolac topcoat; the tanks, pits, trenches, sumps, and secondary containment get immersion-grade linings, with coves, curbs, and penetrations detailed monolithically.
Stamping & Fabrication
Dropped steel, die moves, weld spatter, grinding dust, and steel-wheel carts. The floor is a ¼″ mortar body with an abrasion-resistant topcoat and every joint honored and filled.
Mineral Processing & Reagent Storage
Slurry, abrasive fines, wet floors, and the leaching and flotation reagents stored next door. Process floors get a mortar body; reagent rooms get a chemical-resistant topcoat and lined secondary containment; leach tanks, sumps, and treatment structures get process linings matched to the reagent.
Shipyard & Port Facilities
Fabrication bays, engine and vessel maintenance shops, dockside maintenance buildings, terminal warehouses, shipboard service and utility spaces, and the secondary containment at marine fuel storage terminals. Fuel, hydraulic oil, weld, salt from the quay, and hard-wheel traffic set the build.
| Zone | Primary Exposure | Typical Starting Point | Nominal Thickness |
|---|---|---|---|
| Foundry & Casting Floors | Dropped castings, abrasive sand, heat cycling, hard-wheel traffic | MavClad EM epoxy mortar for impact zones; MavCrete UM where heat cycling and washdown are present | ¼″ |
| Machining & CNC | Coolants, cutting oils, chips and swarf, slip | MavCoat PC or HB epoxy with slip-resistant broadcast; MavClad EM at machine bases and main aisles | — |
| Plating, Pickling & Galvanizing Lines | Acid and caustic baths, rinse water, fume condensate, immersion at tanks and pits | MavCoat NV novolac over a MavClad EM or MavCrete UM body; tank, pit, and containment linings engineered to the bath chemistry | ¼″ |
| Stamping & Fabrication | Dropped steel, die handling, weld spatter, hard-wheel traffic | MavClad EM epoxy mortar with MavSeal UHD topcoat; MavJoint JF in every joint | ¼″ |
| Mineral Processing & Reagent Storage | Slurry and abrasive fines, wet service, reagent spills, leach and treatment immersion | MavClad EM or MavCrete UM body; MavCoat NV topcoat; containment and process linings at reagent storage, leach tanks, and sumps | ¼″ |
| Shipyard & Port Facilities | Fuel and hydraulic oil, weld and grinding, salt and moisture, hard wheels | MavClad EM in heavy bays; MavCoat HB or PC with MavSeal UPA topcoat in shops; lined containment at fuel terminals | — |
Starting points, not prescriptions. Every Maverick system is engineered to the condition of the substrate, the abuse it takes, and the facility’s history with previous floors — the build changes from room to room and plant to plant. Only new construction over bare concrete comes close to a standard build.
Metals, Mining & Maritime Facilities
From the melt shop to the machine shop to the mill floor, these are the facility types this work covers — floors, process areas, tank and process linings, secondary containment, and marine and port work.
- Steel mills
- Aluminum production
- Foundries and casting facilities
- Metal stamping facilities
- Welding and fabrication shops
- Precision machining facilities
- CNC manufacturing
- Metal plating and finishing
- Galvanizing facilities
- Pickling and acid treatment plants
- Ore processing plants
- Mineral processing plants
- Shipbuilding facilities
- Ship repair facilities
The Systems This Work Demands
MavClad EM Epoxy Mortar
¼″ troweled, chemically resistant — the heavy-duty body for impact, abrasion, and hard-wheel zones.
Explore the SystemMavCoat NV Chemical-Resistant Coating
Zero-VOC novolac epoxy for aggressive acid and caustic exposure — the topcoat over mortar bodies on plating, pickling, and reagent floors.
Explore the SystemRepair & Slope Restoration
MavPatch, MavRapidPatch, and MavGrout USP — the slab rebuilt and re-sloped before the system goes down.
Explore the SystemEngineered, Manufactured, and Installed by One Company
Maverick formulates and batches its own resins, engineers each build to the zone it serves, and installs with its own crews under a single-source warranty with a 48-hour response. The work starts at the substrate: prep to sound concrete, section loss and exposed rebar rebuilt, slopes restored, and coves, curbs, sumps, and penetrations detailed monolithically. For plating, pickling, leaching, and reagent service, the chemical exposure is assessed for your facility and the resin is selected against the chemical-resistance chart on each product data sheet — never a generic table.
Heavy Industry Flooring Questions, Answered
Can a resinous floor take dropped castings and steel?
Yes, when the body is built for it. MavClad EM is a quarter-inch trowel-applied epoxy mortar made for heavy-duty industrial traffic and impact, and it is the starting point for stamping, fabrication, and casting-finishing zones. The slab underneath is repaired and re-sloped first, because a mortar floor is only as good as the concrete it bonds to.
What floor goes under a plating, pickling, or galvanizing line?
Typically a troweled mortar body with a MavCoat NV novolac epoxy topcoat, plus lined trenches, sumps, and secondary containment detailed to drain. The tanks and pits themselves get immersion-grade process linings matched to the bath chemistry. Concentration, temperature, and dwell time decide the final build, so the exposure is assessed for your facility and the resin is selected against the chemical-resistance chart on each product data sheet.
Do you install floors in foundries near furnaces?
Maverick engineers the floors around the melt deck and pour line: charging aisles, casting cooling, shakeout, cleaning, and finishing. No resinous floor is a molten-metal surface. Where the slab cycles hot and cold or sees washdown, MavCrete UM urethane cement is the starting point; where impact dominates, MavClad EM epoxy mortar.
Do you work in shipyards and port facilities?
Yes. Maverick engineers floors for fabrication bays, engine and vessel maintenance shops, dockside maintenance buildings, terminal warehouses, and shipboard service and utility spaces, and builds the secondary containment at marine fuel storage terminals. The build follows the exposure: fuel and hydraulic oil, weld and grinding, salt and moisture off the quay, and hard-wheel traffic.
Specify It Once, Correctly
The Architect Center carries the full standard detail library, isometric system shop drawings, and CSI 3-part specifications under Section 09 67 23 Resinous Flooring.
Planning This Work?
Shutdowns, turnarounds, and plants that never stop — bring us the constraint and we will engineer the floor around it.