Understanding the Jack-a-Lope Brewery Challenge
Jack-a-Lope Brewery’s production facility includes:
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Brewing vessels and mash tuns where high-temperature processes occur
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Fermentation tanks that introduce moisture, sugars, and yeast residue
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Distillation equipment for barrel-aged products, exposing floors to alcohol vapors and cleaning solvents
These areas demand a flooring system that is:
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Non-porous & Hygienic: To prevent bacterial growth and absorption of sugars, yeast, and cleaning chemicals.
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Chemical & Acid Resistant: Capable of resisting acids from mashing and fermentation, as well as strong detergents used in daily washdowns.
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Seamless & Easy to Clean: A monolithic surface eliminates grout lines and joints where contaminants could accumulate.
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Durable Under Heavy Loads: Able to withstand forklifts, pallet jacks, and constant foot traffic without cracking or spalling.
Why Sika Urethane Mortar Is Perfect for Brewery Floors
Sika urethane mortar systems are extensively used in food and beverage facilities due to their ability to meet and exceed USDA flooring standards. Key benefits include:
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USDA Compliance: Urethane mortar systems are formulated to resist microbial growth and meet USDA and FDA guidelines for food processing environments. The non-porous finish prevents moisture and bacteria from seeping into the substrate.
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Exceptional Chemical Resistance: The cured urethane mortar resists acids, solvents, and high-proof alcohols. This is critical in brewing and distillation areas where spills of wort, mash acids, and cleaning agents are routine.
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High Impact & Abrasion Resistance: Urethane mortar withstands heavy rolling loads, dropped tools, and scraping from equipment, ensuring longevity even under the toughest conditions.
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Thermal Shock Tolerance: Repeated exposure to hot cleaning cycles and cold beverages can cause thermal stress. Urethane mortar’s formulation allows it to expand and contract without delaminating or cracking.
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Fast Cure & Minimal Downtime: Depending on conditions, many Sika urethane systems cure to light foot traffic within 24 hours—minimizing production interruptions at Jack-a-Lope Brewery.
TKO Concrete Coatings’ Installation Process
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Surface Preparation & Repair:
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Using concrete grinders, TKO began by profiling the existing substrate to a CSP (Concrete Surface Profile) appropriate for urethane mortar adhesion.
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Any cracks, spalls, or joint gaps were patched with high-strength epoxy grout to ensure a uniform, level surface.
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Primer Application:
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We applied a Sika primer designed for high-moisture environments, sealing the slab and improving adhesion for the subsequent mortar layer.
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Base Coat & Mortar Broadcast:
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A base coat of Sika urethane mortar was troweled onto the prepared concrete at the specified thickness (typically ¼” to 3/8”).
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While still wet, broadcast quartz sand or Sika’s graded aggregate into the base coat to create a textured profile for slip resistance and mechanical bonding.
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Top Coat & Seal:
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After initial curing, excess broadcast material was swept off, and a second urethane mortar layer was applied to encapsulate the aggregate and achieve a fully sealed, seamless surface.
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Finally, a clear Sika urethane top coat was applied, providing UV stability (to prevent yellowing), enhanced chemical resistance, and easy cleanup for daily washdowns.
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QA/QC & Final Inspection:
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TKO technicians conducted bond tests and performed slip-resistance checks (ASTM D2047), ensuring the floor met Jack-a-Lope’s safety and performance requirements.
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A post-installation inspection with Jack-a-Lope’s facility managers confirmed the entire 12,000-square-foot brewing, fermentation, and distillation area met USDA guidelines.
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Why TKO Concrete Coatings Excels in USDA-Compliant Food & Beverage Floors
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Specialized Industry Knowledge: TKO has completed numerous food and beverage flooring projects, including bakeries, breweries, beverage plants, and commercial kitchens throughout Nashville, Franklin, and Lebanon. Our understanding of USDA and FDA requirements ensures compliant, hygienic installations every time.
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Premium Materials & Expert Craftsmanship: We select top-tier Sika urethane mortars—known for their performance in wet, high-acid, and high-abrasion environments. Our certified installers follow manufacturer protocols to deliver seamless, long-lasting floors.
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Local Responsiveness & Minimal Downtime: As a Nashville-based company, TKO accommodates tight production schedules, often working nights or weekends to minimize operational disruptions. Rapid cure urethane systems allow Jack-a-Lope to resume operations within 24–48 hours.
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Comprehensive Warranties & Ongoing Support: We stand behind every brewery flooring installation with robust material and labor warranties. Our team remains available for maintenance advice, periodic inspections, and any future expansions.
Conclusion: A Proven Flooring Solution for Breweries
TKO Concrete Coatings is proud to have partnered with Jack-a-Lope Brewery to install a Sika urethane mortar flooring system—providing a seamless, non-porous surface that meets rigorous USDA requirements and thrives under constant moisture, chemical exposure, and heavy traffic. Whether you operate a craft brewery, large-scale beverage production plant, or any food and beverage facility, TKO’s specialization in USDA-compliant flooring ensures you receive a hygienic, durable, and low-maintenance solution that keeps you brewing without interruption.
For a free consultation and estimate on your brewery or food-grade flooring project, call 615-414-3727 or visit www.tkoconcrete.com. Trust Nashville’s experts in brewery floor restoration to keep your operations running smoothly and safely—just like Jack-a-Lope Brewery.
