The Situation

In 1995, Kym and Pete Buttschardt opened the first Roosters Brewing Company on Historic 25th Street in Downtown Ogden, Utah. The restored 119-year-old building with a unique ambiance and outdoor patio made the 25th Street location a perfect place for meeting friends. 

Roosters quickly became “the place to go” and a community gathering spot for Ogden's diverse and eclectic population. It's not unusual to see mud-splattered mountain bikers enjoying burgers and brews at one table while more formally dressed couples enjoy herb-crusted rack of lamb and fine wine at another.

Twenty years later, Roosters Brewing Company opened a new brewery, Roosters B Street, in the new Trackline development in Ogden. In addition to approximately 13,000 sq. ft. of brewery, dining, and tap room space, the campus features an additional 6,000 sq. ft. of space for retail and manufacturing.

Breweries are demanding beverage production environments for flooring. The wide temperature range of the water and its resulting thermal shock on the concrete floor when released, causes delamination to normal epoxy coating systems, resulting in complete floor failure. Breweries require high up time for their production areas and cannot afford to have a floor out of service.  

Roosters Brewery owners sought a flooring solution that was long lasting, had excellent chemical and stain resistance, and was designed to withstand harsh thermal shock. They selected Laticrete’s Spartacote Urethane Cement with Spartacote Flex Pure Clinical Plus with traction additive as the solution to their 9,000 sq, ft, (836 m2) demanding brewery production floor.  

The Solution 

The success of any resinous flooring project is always predicted upon good concrete surface prep. Without proper prep, resinous flooring projects often result in failure due to surface contaminants, laitance and other bond breaking agents. Spartacote Urethane Cement is no different, requiring a Concrete Surface Profile 4, which is best achieved by shot blasting the existing concrete.  

The coatings crew spent two days preparing the new concrete prior to applying the Spartacote Urethane Cement. They fixed cracks and spalls with Spartacote Fast Fix, a two-part, hybrid urethane crack repair material. They vacuumed and swept up the entire floor once surface prep was complete, keeping it as clean as possible for the Spartacote urethane cement application. 

Next, the resinous flooring crew began mixing the four-part Spartacote urethane cement material. For this brewery project, each batch consists of a Part A resin, a Part B hardener, a Part C aggregate, and a Part D red pigment pack. The crew mixes the Part A and Part B together, then adds the Part D pigment pack. Finally adding the Part C aggregate, all mixed in a 6-gallon pail (22.71 L). These are heavy batches, each weighing approximately 70 lbs. (37.75 kg). Noting this, the crew used a wheeled transporter to move material to the opposite end of the building for easy transport to start the application process.  

The resinous flooring crew begins by pouring out the Spartacote Urethane Cement and spreading out the material using a gauge rake set to 3/16th inch (76.2 mm). This elevation gives an application rate of approximately 42 sq ft (3.9 m2) per kit. After spreading out the urethane cement material, another crew member immediately backrolls the material with a spiked roller, leveling the urethane cement out over the floor. The coatings crew repeated the mixing and placing process for approximately 6 hours until all 9,000 sq ft (836 m2) of the brewery was covered with Spartacote Urethane Cement. This continuous process was imperative to maintain the wet edge of the material to prevent resinous flooring failure. Once resinous flooring crews start the job, they cannot stop. Since Spartacote urethane cement requires an eight-hour cure time, the resinous flooring crew was finished for the day after the floor was covered in wet material.  

The next day, the coatings crew prepared the top coat for the resinous flooring system. This top coat is Flex Pure Clinical Plus pigmented bright red with Spartacote GRIP traction additive. The floor owners picked this color because it aligns with Rooster Brewery’s logo and branding. The resinous flooring crew staged the material at one end of the building for mixing and began dispersing Spartacote pigment to the Part A. They then mixed in the Part B for two minutes with a slow speed drill. Using the same transporter, they began applying the Flex Pure Clinical Plus material at the opposite end of the new building, working their way back to the staging and mixing area.  

The coatings crew poured out a ribbon of mixed material and immediately squeegeed it onto the surface. Following the squeegee, four crew members on spikes began rolling the material out in a perpendicular fashion. Lastly, one crew member followed the four Flex Pure Clinical Plus resinous material was applied at 200 sq ft (18.58 m2) per gallon. The coatings crew worked in this fashion for approximately one hour until the process was complete and the entire 9,000 sq. ft. (836 m2) of floor space was covered in bright red, resinous material. The Flex Pure Clinical Plus top coat provided the brewery with antimicrobial protection and excellent abrasion, stain, and chemical resistance. Curing in two hours, this Spartacote floor allows for fast return to service. When combined with Spartacote Urethane Cement, this resinous flooring system gives floor owners heavy duty impact protection as well. 

“The two small breweries in Ogden and Layton have been at capacity for the last couple of years,” said owner Pete Buttschardt. “In order to keep the shelves stocked and expand, we’ve been working to create a dedicated production facility and move to canning. This new facility really matches our brand and our vision. We couldn’t be more excited for what this means for Roosters Brewing Company.”