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Areas of Application
Polyurethane Concrete Flooring
Star Floor Shield – 4K
Self-Levelling Polyurethane Concrete Flooring for Food-Grade & Heavy-Duty Industrial Floors
Star Floor Shield – 4K is a heavy-duty, four-component polyurethane concrete flooring system that lays down as a seamless, self-levelling screed just 3–6 mm thick. Built for the toughest processing environments — food and beverage plants, dairies, breweries, commercial kitchens, and pharma facilities — it delivers a dense, matt, hygienic floor that shrugs off thermal shock from –40 °C to +120 °C, hot washdowns, and even steam cleaning.
Unlike ordinary epoxy floors, this polyurethane cementitious flooring resists organic acids, alkalis, fats, oils, and aggressive sanitisers, and can be applied over concrete with up to 10 % residual moisture. With full traffic in 24–48 hours and a monolithic surface that does not support bacterial growth, Star Floor Shield – 4K keeps hygiene-critical floors audit-ready and production running.
Key Performance Benefits of Our Star Floor Shield – 4K
- Extreme Thermal-Shock Resistance — Handles –40 °C to +120 °C at 6 mm; steam-cleanable without cracking.
- Hygienic & Seamless — Monolithic, easy-clean surface that does not support bacterial growth; HACCP-oriented.
- Broad Chemical Resistance — Stands up to organic acids, alkalis, fats, oils, sugars, and sanitising agents.
- Moisture Tolerant — Applies over concrete with up to 10 % residual moisture, even on young slabs.
- Fast Return to Service — Full traffic in 24–48 hours; full chemical cure in just 5 days.
- Near-Zero Pinhole Finish — Built-in CO₂-scavenging chemistry delivers a dense, smooth matt surface.
GET A FREE QUOTE
Talk to an expert.
Our technical team will assess your requirement, recommend the right solution, and send you a detailed quote — at no cost.
An ESCO recognized leader in the industry
Request your free quote
Fill in the form and we will be in touch within 24 hours.
Request received!
Our team will review your details and get back to you within 24 hours.
The Problem
3 Reasons Ordinary Floors Fail in Food & Processing Plants
Thermal Shock Cracks and Delaminates Ordinary Floors
Hot washdowns, steam cleaning, boiling spills, and freezer-to-oven temperature swings make epoxy and conventional floor coatings crack, blister, and peel away from the concrete — forcing repeated shutdowns for repairs.
Joints and Damaged Floors Harbour Bacteria
Cracks, joints, and pinholes in worn flooring trap food residues, moisture, and bacteria — creating hygiene risks that fail HACCP and food-safety audits and put your product and reputation on the line.
Acids and Cleaning Chemicals Eat Away Floor Coatings
Lactic, acetic, and citric acids, fats, oils, sugars, and daily sanitising chemicals steadily attack standard floor coatings — leaving etched, stained, and softened surfaces that need constant patching and recoating.
Benefits
6 Powerful Benefits That Make Star Floor Shield – 4K the Ultimate Polyurethane Concrete Flooring
Star Floor Shield – 4K combines six powerful benefits in one polyurethane cementitious flooring system — extreme thermal-shock resistance, seamless hygiene, broad chemical resistance, heavy-duty strength, moisture tolerance with fast return to service, and low-VOC application. It's the complete PU concrete floor for food, beverage, pharma, and heavy industrial environments.
Extreme Thermal-Shock Resistance
Star Floor Shield – 4K performs from –40 °C to +120 °C at 6 mm thickness — so it takes steam cleaning, hot washdowns, boiling spills, and freezer conditions in stride. Its thermal expansion closely matches concrete, keeping the floor bonded through every temperature swing.
Hygienic, Seamless & Easy to Clean
This polyurethane concrete flooring cures into one monolithic, joint-free surface that does not support bacterial growth. With a near-zero pinhole finish from built-in CO₂-scavenging chemistry, it supports HACCP-oriented operation and keeps food and pharma floors audit-ready.
Broad Chemical Resistance
Organic acids like lactic, acetic, and citric, dilute inorganic acids, alkalis, fats, oils, sugars, and everyday cleaning and sanitising agents — Star Floor Shield – 4K resists them all, protecting your floor through years of aggressive processing and daily washdowns.
Heavy-Duty Mechanical Strength
With over 50 N/mm² compressive strength, excellent abrasion and impact resistance, and pull-off adhesion so strong the concrete fails first, this PU concrete screed carries forklifts, pallet trucks, and constant traffic without wearing thin.
Moisture Tolerant, Fast Return to Service
Star Floor Shield – 4K can be applied over concrete with up to 10 % residual moisture — even on slabs just 7–10 days old. The floor takes light traffic in 12–16 hours, full traffic in 24–48 hours, and reaches full chemical cure in only 5 days.
Low VOC, Low Odour Application
Solvent-free once mixed, with VOC below 100 g/L and very low odour during application, Star Floor Shield – 4K can be installed close to sensitive production areas. Choose from Red, Green, Blue, Yellow, and Grey in a smooth matt finish, with a textured broadcast option for wet areas.
How to Apply
Method of Application
Surface Preparation & Scratch Coat
Start with sound concrete of at least 25 N/mm² compressive strength. Shot-blast or scarify to remove laitance, repair defects, and cut anchor grooves at all edges, doorways, and drains. Then seal the substrate with a 1 mm scratch coat of Star Floor Shield – 4K — priming porous surfaces first — and rectify any pinholes before the topping goes down.
Mixing
Use complete pre-weighed 20 kg kits only — never part-mix. Pre-stir the Base, blend in the Colorant until uniform, add the Hardener and mix for 30 seconds, then gradually add the Aggregate and mix for 2.5–3 minutes in a forced-action mixer. Work within the 15–20 minute pot life at 25 °C.
Laying & Finishing
Pour immediately and spread with a pin rake or serrated trowel to 3–6 mm. Spike-roll straight away in overlapping passes — within 10 minutes of laying — to release trapped air, keep a wet edge to avoid cold joints, and protect the finished floor from moisture and traffic for 24 hours.
Customer Stories
Client Success Stories
FAQs
Frequently Asked Questions
What is Star Floor Shield – 4K and where is it used?
Star Floor Shield – 4K is a four-component, self-levelling polyurethane concrete flooring system laid at 3–6 mm. It's designed for food and beverage processing, dairies, breweries, commercial kitchens, pharmaceutical plants, cold rooms, chemical processing areas, and warehousing or loading areas exposed to thermal or chemical attack.
How is polyurethane concrete flooring different from epoxy flooring?
Polyurethane concrete (PU concrete) handles far greater thermal shock than epoxy — Star Floor Shield – 4K withstands –40 °C to +120 °C at 6 mm, including steam cleaning, where epoxy floors typically crack and delaminate. It also tolerates up to 10 % residual substrate moisture and resists organic acids that attack epoxy.
Can Star Floor Shield – 4K floors be steam cleaned?
Yes. Applied at 6 mm thickness, the floor withstands –40 °C to +120 °C, making it fully steam-cleanable — ideal for hygiene-critical food, dairy, and beverage areas that need aggressive hot washdowns.
What thickness should I choose — 4 mm or 6 mm?
A 4 mm build (rated –20 °C to +100 °C) suits most processing and engineering areas. Choose 6 mm (rated –40 °C to +120 °C) for severe thermal shock, freezers, cold rooms, and areas that are steam-cleaned. Both include the 1 mm pinhole-sealing scratch coat.
How soon can the floor return to service?
Fast. At 25 °C the surface is dry in 4–6 hours, takes light traffic in 12–16 hours, full traffic in 24–48 hours, and reaches full chemical cure in just 5 days — keeping production downtime to a minimum.
Which chemicals can Star Floor Shield – 4K resist?
It offers broad chemical resistance against organic acids such as lactic, acetic, and citric acid, dilute inorganic acids, alkalis, fats, oils, sugars, and common cleaning and sanitising agents used in food and pharmaceutical facilities.
Can it be applied on new or damp concrete?
Yes. Star Floor Shield – 4K is moisture tolerant and can be applied to concrete with up to 10 % residual moisture — including slabs as young as 7–10 days old — provided there is no rising damp or osmosis risk and the surface is properly prepared.
Is Star Floor Shield – 4K hygienic and suitable for food areas?
Yes. The cured floor is monolithic, seamless, and easy to clean, does not support bacterial growth, and supports HACCP-oriented operation — making it well suited to food, beverage, dairy, and pharmaceutical environments.
How much material do I need per square metre?
Consumption is approximately 2.0 kg/m² per mm of thickness — about 8 kg/m² at 4 mm and 12 kg/m² at 6 mm. One pre-weighed 20 kg kit covers roughly 2.5 m² at 4 mm or about 1.7 m² at 6 mm.
What colours and finishes are available?
Star Floor Shield – 4K comes in Red, Green, Blue, Yellow, and Grey standard shades (other shades on request) with a smooth matt finish. A textured broadcast option is available for wet areas needing extra slip resistance.