Fosroc Nitoflor Floorcrete PU
A flow-applied, solvent-free cementitious polyurethane (PU) floor topping for heavy-duty hygienic industrial floors that face chemicals, thermal shock and abrasion.
What is it?
A high-performance, chemically-cured, solvent-free self-levelling cementitious polyurethane (PU) floor topping (binder: polyol + polyisocyanate) laid at 4-9 mm to give a seamless, chemical- and abrasion-resistant floor.
Where is it used?
Food & beverage plants, pharmaceutical and medical production floors, breweries and dairies, warehouses, traffic aisles, chemical plants, power plants, basement parking, textile/garment units, hospitals and laboratories.
Why use it?
Withstands aggressive acids/alkalis, thermal cycling up to ~130C (occasional spillage to 150C, steam cleaning in the 9 mm system), heavy traffic and impact, while staying odourless and VOC-free for occupied/hygienic environments.
How is it applied?
Prepared substrate is primed; the proportionate four-component pack is mixed (base + colorant, then curing agent and graded aggregate) and immediately spread with a steel trowel to the required thickness; light traffic in 24 hrs, full cure in 3 days.
About Fosroc Nitoflor Floorcrete PU
Fosroc Nitoflor Floorcrete PU is the cementitious polyurethane (PU) screed/topping in the Nitoflor resin-flooring family, supplied to the Indian market through Fosroc’s local manufacturing as part of its constructive-solutions range. Unlike a conventional epoxy floor, Floorcrete PU combines a polyol/polyisocyanate binder with graded mineral aggregates and a cementitious filler, producing a dense, robust topping that is far more forgiving of heat, moisture vapour and thermal shock than standard epoxy systems. It is a chemically-cured, solvent-free, self-levelling material (97-98% solids, VOC below 20 g/L) that is laid as a seamless monolithic layer, typically at 4 mm for medium-duty service and 9 mm where the floor must take steam cleaning, boiling-water wash-down or heavier mechanical loads. The cured surface is non-skid, easy to clean and resistant to acids, alkalis, salts, oils and food-industry contaminants, which is why it is a default specification for hygienic process floors. For food and pharmaceutical environments the system is normally over-coated with two 80-100 micron coats of a PU finish to meet hygiene-compliance requirements. The product was formerly marketed as BP Floorcrete PU, so older specifications and tender documents may still reference that name; they describe the same system. For Space Arc Engineering’s clients across Delhi NCR and Pan-India, Floorcrete PU sits in the heavy-duty, wet-process, thermal-shock band of the flooring portfolio rather than the lighter decorative-epoxy band.
The technical insight
The defining feature of a cementitious-PU topping like Floorcrete PU is its coefficient of thermal expansion (around 2.5 x 10^-1 per degC per the TDS) and high thermal tolerance: the coating does not begin to soften until temperatures exceed roughly 130C, with fully-serviceable specifications to ~130C, resistance to occasional spillage to 150C, and a 9 mm build that survives routine steam cleaning and boiling water/hot-oil discharge. This thermal robustness, combined with ~50 MPa compressive strength and Shore D hardness of ~83, is what separates it from a standard epoxy self-leveller, which would soften or de-bond under the same conditions. Practically, the short 15-20 minute pot life means it must be mixed in full proportionate packs (never split) and trowelled immediately; the four-part by-weight ratio (Base 2.58 : Curing agent 3.28 : Aggregate 13.94 : Colorant 0.2 in a 20 kg unit) is non-negotiable for achieving the rated mechanical properties.
Where it is used
- Food and beverage processing plants and bottling lines requiring wash-down and hot-water hygiene
- Pharmaceutical and medical production floors (over-coated with PU finish for hygiene compliance)
- Breweries, dairies and cold-store/wet-process areas with thermal cycling
- Warehouse and factory traffic aisles, loading bays and forklift routes
- Chemical and process plants exposed to acid, alkali and solvent spillage
- Power plants and heavy engineering shop floors
- Basement and multi-storey car-park decks
- Textile and garment manufacturing floors
- Hospitals, laboratories, corridors and institutional buildings
Key advantages
- Seamless, jointless monolithic finish that is easy to clean and hygienic
- Withstands service temperatures to ~130C, occasional spillage to 150C; 9 mm system tolerates steam cleaning and boiling-water wash-down
- High compressive strength (~50 MPa) and Shore D ~83 hardness for heavy traffic and impact
- Excellent abrasion resistance (<0.05 mm by BS 8204; 118 mg Taber CS17)
- Broad chemical resistance to acids, alkalis, salts, oils, fats and food acids
- Bond/pull-off strength exceeds the cohesive strength of the concrete (concrete-failure mode)
- Solvent-free and odourless (VOC <20 g/L) – suitable for occupied and food/pharma areas
- Fast return to service: light traffic in 24 hrs, full cure in 3 days
- Available in cream and grey tones, with RAL shades to order
Limitations & considerations
- Very short pot life of 15-20 minutes demands trained applicators, batch discipline and full-pack mixing – not a DIY product
- Substrate is critical: concrete must be 28-30 days old, pull-off strength >=1.5 N/mm2, compressive strength >=25 N/mm2, pH <=10 and free of curing compounds/sealers
- Sensitive to substrate moisture – above 30% RH two coats of primer are required, and rising damp must be eliminated first
- Application window is narrow: substrate temperature 20C (min) to 40C (max), which needs management on Indian summer/monsoon sites
- Must not be thinned and no solvent may be added; aggregate component has a shorter 6-month shelf life vs 12 months for the resins
- For food/pharma hygiene compliance an additional PU finish (two coats, 80-100 micron) is needed over the topping
- Skilled trowel application is required to control thickness and minimise entrained air
Selection & best practice
Treat the concrete, not the coating, as the project risk. Always confirm the slab is at least 28-30 days old with pull-off strength >=1.5 N/mm2, compressive strength >=25 N/mm2 and surface pH <=10, then mechanically prepare it by enclosed shot-blasting or scarifying to an open, dust-free texture. Verify substrate moisture (use two primer coats above 30% RH and rule out rising damp with a DPM), prime with the recommended Nitoflor primer, and let it cure overnight. On site, work to the 20-40C substrate-temperature window – schedule pours for cooler parts of the day in NCR summers – and mix only full, unsplit proportionate packs, spreading immediately within the 15-20 minute pot life. Specify 9 mm where steam cleaning or boiling wash-down occurs and 4 mm for general medium-duty areas, and add the PU hygiene finish for food and pharma zones. Insist on a trained applicator and keep light traffic off for 24 hrs and heavy traffic for 3 days.
Specifications
| System type | Flow-applied / self-levelling cementitious polyurethane (PU) floor topping; chemically-cured, solvent-free |
| Binder / composition | Polyol & polyisocyanate binder with graded inert aggregate; lightfast, lead-free pigments |
| Compressive strength | Around 50 MPa (DIN EN ISO 604) |
| Flexural strength | Around 16 MPa (DIN EN ISO 178) |
| Shore D hardness | Around 83 |
| Abrasion resistance | <0.05 mm (C&CA / BS 8204); Taber 118 mg (CS17 wheels) |
| Bond / pull-off strength | Greater than cohesive strength of concrete; concrete-failure mode (ASTM D4541 / BS 6319) |
| Density | 1.85 g/cm3 (BS 6319) |
| Recommended thickness | 4 mm (medium-duty) to 9 mm (heavy-duty / steam-cleanable) |
| Temperature resistance | Serviceable to ~130C; occasional spillage to 150C; 9 mm system withstands steam cleaning |
| Solids content / VOC | 97-98% solids; VOC <20 g/L |
| Pot life | 15-20 minutes (atmosphere dependent) |
| Curing times | Initial cure / light traffic 24 hrs; full cure / heavy traffic 3 days |
| Theoretical coverage | ~1.45 sq.ft per kg at 4 mm thickness |
| Mixing ratio (by weight) | Base 2.58 : Curing agent 3.28 : Aggregate 13.94 : Colorant 0.2 (per 20 kg unit) |
| Pack size | 20 kg unit (Base 2.58 kg, Curing agent 3.28 kg, Aggregate 13.94 kg, Colorant 0.2 kg) |
| Colour range | Cream and grey tones; RAL shades available to special order |
| Substrate requirements | Concrete pull-off >=1.5 N/mm2, compressive >=25 N/mm2, age 28-30 days, pH <=10, substrate temp 20-40C |
| Shelf life | Resin parts 12 months; aggregate 6 months at 25C unopened |
Industry use cases
Food & Beverage
Bottling halls, processing and packing areas where the floor faces food acids, fats, hot-water wash-down and forklift traffic; the 9 mm steam-cleanable build with a PU hygiene finish is specified for wet zones.
Pharmaceutical & Healthcare
Production floors, clean corridors and labs requiring a seamless, easy-to-sanitise surface; over-coated with two 80-100 micron PU finish coats to meet hygiene compliance.
Warehousing & Logistics
Traffic aisles, loading bays and forklift routes where the priority is abrasion and impact resistance plus a fast 24-hour/3-day return to service to limit downtime.
Chemical & Process Industry
Plant floors and bunded areas exposed to acid, alkali and solvent spillage, where the broad chemical-resistance profile and concrete-failure bond strength protect the slab.
Power & Heavy Engineering
Turbine halls, machine shops and switchgear rooms needing a hard (Shore D ~83), ~50 MPa floor that resists thermal load and dropped-tool impact.
Frequently asked questions
Is Fosroc Nitoflor Floorcrete PU an epoxy or a polyurethane floor?
What thickness should I specify – 4 mm or 9 mm?
What temperature can it withstand?
What are the substrate and curing requirements?
Is it food-safe and low-odour?
Was this product previously called something else?
How we position Fosroc Nitoflor Floorcrete PU
Within Fosroc’s Nitoflor range, Floorcrete PU is the cementitious-polyurethane, heavy-duty, thermal-shock option – positioned above the standard epoxy self-levellers and chosen specifically for wet, hot, hygienic process environments. It sits alongside Fosroc’s epoxy-PU topping Nitoflor EPU3000 and the high-build self-levelling epoxies in the Nitoflor SL3000 family, with Nitoflor SLE/Floorcrete primers handling the substrate; on the Australian/export side the same cementitious-PU need is met by Nitoflor PU200/PU600. Where Floorcrete PU’s thermal resistance is overkill – e.g. dry, ambient-temperature warehouse or showroom floors – a decorative epoxy self-leveller is the more economical specification. For credible alternatives in the Indian market, the comparable cementitious-PU and resin-flooring systems are Sika’s Sikafloor PurCem range (a direct functional competitor for food/beverage thermal-shock floors), MBCC/Master Builders Solutions Ucrete (the benchmark heavy-duty PU concrete for the harshest hot/wet plants), STP Limited’s flooring systems, and Dr. Fixit/Pidilite resin floor coatings for lighter-duty applications. As an authorised Fosroc distributor and applicator, Space Arc Engineering supplies and installs Nitoflor Floorcrete PU across Delhi NCR and Pan-India, and can advise where it is the right fit versus a lighter epoxy or a competing PU-concrete system based on your slab condition, thermal exposure and hygiene requirements.
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