Cracked floors around drains are one of the most common and troublesome maintenance and sanitation problems in food production facilities. These cracks compromise the floor’s structural integrity and create a breeding ground for contaminants that cause foodborne illnesses, costly product recalls, reputational harm, and disruptions to operations.
Fortunately, these challenges can be fully addressed with a well-designed, modern drain system. It begins with a robust drain design and solid construction, but true durability is achieved through a holistic approach that addresses all three major flooring components: the concrete itself; the protective floor coating; and the drains integrated into the system
This coordinated method relies on custom-engineered hardware and superior installation techniques.
THE CHALLENGE
Drains represent the most vulnerable point in any food plant flooring, as they are regularly subjected to vibrations, impact, heavy rolling loads, and harsh fluids.
Modern drain designs directly address these pain points through smarter engineering, stronger materials, and better floor integration. The process starts with picking the right drain for the application.
Choosing stainless steel should be non-negotiable. Steer clear of outdated concrete trenches, they are inefficient and prone to delamination. Concrete’s porous nature traps bacteria, making effective sanitation nearly impossible. Even for underground piping, stainless steel proves superior. While CPVC offers some durability, it cannot withstand severe heat. For instance, pouring boiling water into a stainless-steel drain leaves the drain intact, but CPVC pipes below may soften or collapse.
Different areas need specific drainage solutions, so understanding the options is essential. The three primary drain types, area drains, grated trench drains, and slot drains, each bring distinct advantages and drawbacks.
Traditional area drains work well for small spaces but struggle in larger areas. They rely on extensive underground piping, increasing costs, complicating maintenance, and raising the risk of blockages and bacterial growth.
Grated trench drains once dominated but present their own concerns. Grates are heavy, awkward to clean, trap debris and bacteria, and are prone to chipping and corrosion.
Slot drains now lead the way in food sector upgrades. Their single, slender slot eliminates the need for grates, dramatically reducing places microbes can hide and vastly simplifying cleaning.
SLOT DRAIN ADVANTAGES
One of the key advantages of slot drain design is its ability to minimize floor cracking by more effectively managing load and vibration. Unlike traditional grated drains, the narrow profile of slot drains distributes weight and impact across the entire system, transferring more of the load from the drain to the surrounding floor. This design minimizes stress on both the drain and its connection to the floor, providing enhanced durability and stability.
Additionally, slot drains also resolve common problems found in grated drains, like misaligned or damaged grates that can shift and bounce, increasing the wear and tear caused by heavy loads and movement.
Selecting drains with the correct load class is especially critical in areas exposed to heavy traffic, such as forklifts with hard pneumatic tires or heavy carts. Using drains not rated for these loads can result in flexing, which leads to delamination and cracking of the surrounding floor system.
Structural strength is everything. High-quality slot drains incorporate advanced reinforcement features to withstand heavy loads and vibrations. The strongest slot drains are reinforced with stainless steel angles. These angles add rigidity, preventing flexing and maintaining the drainage system’s strength.
Another critical feature is the use of steel embeds, metal components welded to the drain that tie into the floor’s rebar and are encased in concrete during pouring. This design solidifies the connection between the drain and the flooring substrate, creating a unified structural unit that resists shifting and ensures long-term stability.
BONDING FLOOR COATING AND DRAIN
Another important feature of advanced drain systems is that they are designed to ensure a tight and lasting bond between the floor coating and the metal drain. Proper adhesion of the floor coating to the drain is achieved through a design featuring a lip that extends perpendicularly into the floor, significantly increasing the surface area for the coating to adhere to the metal drain. This ensures a strong and durable bond. The lip area undergoes specialized surface treatments, including primers and mechanical processes, to enhance adhesion. Since stainless steel’s chromium oxide layer naturally resists bonding, these proven methods are essential for achieving a permanent, seamless attachment between the floor coating and the stainless-steel surface.
ENSURING A SEAMLESS INSTALLATION
Cracks around drains often result from substandard installation practices. When constructing the floor, grade the slopes properly to prevent water pooling, extending the life of both the floor and coating while improving sanitation and reducing cleaning effort.
The keyway is crucial for proper installation. It is a groove in the concrete where the drain lip sits. If the keyway is too narrow to allow the floor coating to flow in during installation, the concrete will press directly against the lip of the drain. This creates a weak point where fluids can seep in, causing contamination. On the other hand, if the keyway is too wide, it compromises the structural integrity of the floor coating that will fill the space.
Proper installation of the floor coating is just as important as the floor construction. The concrete substrate, including keyways, must be thoroughly cleaned and free of dust and debris to allow the floor coating to adhere properly. Both the concrete surface and the stainless steel lip of the drain system must be primed. This ensures the floor coating bonds effectively to both surfaces, providing a durable seal.
In addition to preparation and priming, one of the most frequent causes of premature floor failure is the application of insufficient coating thickness. While manufacturers specify minimum thicknesses for optimal performance, installers sometimes apply less material than required, whether to save on costs or due to time pressure. This shortcut can lead to weak spots, poor adhesion, and early delamination, especially in high-traffic or wet areas. To ensure long-term durability, project specifications should clearly state the required coating thickness, and quality control checks during installation should verify compliance.
Many common floor and drain failures can be prevented at the design stage. Including detailed requirements for floor preparation, keyway dimensions, coating thickness, and drain selection in construction documents ensures that best practices are followed during installation. Early collaboration between engineers, architects, and installers is essential for long-term success.
about the author
Viking Kristjansson is vice president sales engineering at Global Drain Technologies.