How to make a durable and safe floor for trucks

The Kömmerling poured floor system is highly durable and flexible. It is approved for food contact and is physiologically safe, making it the ideal choice for food transport trucks. Due to its resistance to mechanical influences and the possibility of easy repair, this system is very popular among truck owners and box body manufacturers.

Körapur 689

Körapur 689 is a product that is part of this system. It is a cast floor that is normally applied in a thickness of 3-5 mm. This product is designed to level the subfloor and create a continuous floor layer. It can be used for application on various materials such as polyester, aluminium, steel plates and wood.

Körapur 690

Another product is Körapur 690 - a covering, coating layer suitable for various materials, particularly suitable for anti-slip floor treatment for vehicles used for transporting fresh goods, meat, fish and for refrigerated transport vehicles. The anti-slip treatment can be created using a special roller that can be supplied with this product. Körapur 690 contains a polyurethane component and is particularly suitable for vans, box trucks and flatbed trucks. The product is very resistant to mechanical loads and chemicals once cured.

Körapox BS 85

The last product in this system is Körapox BS 85. This product is also intended as a covering layer that can form a smooth surface after application or can be modified with silica sand or corundum grains to provide a slip-resistant coating for high resistance floors, against mechanical damage in trucks and other vehicles. Like the other products in this system, it is suitable for application to a variety of materials and is particularly suitable for vehicles used to transport fresh goods such as dairy products, vegetables, meat, fish. This product can also be used in uncovered areas as it better resists sunlight. Körapox BS 85 contains an epoxy base.

How to choose the right product

Choosing the right product depends on the specific requirements and needs of the truck owner or bodybuilder's project. It is recommended to consult an application specialist to help select the most suitable type of cast floor for the type of load, floor or vehicle.

Special solutions for refrigerated and reefer vehicles

Refrigerated and refrigerated vehicles represent a specific category in the freight transport sector. These types of vehicles require special modifications to be able to maintain low temperatures while handling the harsh conditions associated with transporting refrigerated and frozen products.

Kömmerling's cast floor system is the ideal solution for these specific requirements as well. The products Körapur 689, Körapur 690 and Körapox BS 85 have been tested and proven to withstand temperatures down to -30°C. This means that they are able to withstand the extreme conditions that are typical of refrigerated and freezer vehicles.

The floor in these vehicles must not only be resistant to low temperatures, but also be hygienic and easy to clean. Kömmerling products meet these requirements. They are approved for food contact and are physiologically safe. This means that they are ideal for vehicles that also transport unpackaged food. In addition, the Kömmerling cast floor system offers the possibility of a non-slip finish, which is particularly important in environments where sudden temperature changes and condensation can occur. The non-slip finish reduces the risk of falls and accidents, which contributes to worker safety.

How to apply Kömmerling poured flooring

In this section we look at practical instructions on how to apply Kömmerling solid flooring. This guide is intended for both end customers and traders in the B2B segment.

Step 1: Preparing the substrate

Before applying a poured floor, it is important to prepare the subfloor properly. The subfloor should be clean, dry and free of dust. If the subfloor is made of aluminium, steel, wood or laminate, it is recommended to pre-treat it with a primer for better adhesion. When preparing the substrate, it is important to remove any dirt and dust that could affect the quality of the final surface.

Step 2: Application of the levelling layer

The first layer you apply is the Körapur 689 levelling layer. Apply this product evenly over the entire surface of the substrate. You can use a stainless steel squeegee for even application. This layer helps to smooth out unevenness in the substrate and prepare it for the application of the covering layer.

It is used to adjust unevenness of floors of trucks, containers, sales vehicles, caravans, camping vehicles, and so on. It is applied to polyester, aluminum, primed steel sheet and wood. A test certificate is available on request.

• With a coating thickness of 3-5 mm, one 15 kg pack is sufficient for about 3-4^m2.
  
• Mark this space on the floor.
  
• Pour the hardener into the resin barrel, and allow it to drain completely.
  
• For the purpose of making the covering layer with Körapur 689, mix the resin and the hardener vigorously in a weight ratio of 4 : 1, using a mixing machine, for about 3 minutes (about 400 rpm) until no differences in colour of the mixed mixture are visible.
  
• The recommended processing temperature is 22°C.
  
• Transfer the mixed mixture to another clean container. In this container, stir the mixture thoroughly for a further 2 minutes. Only take the material to be processed from this second container.
  
• The mixing process must be carried out thoroughly but should not take more than 5 minutes.

Spill the contents of the mixing vessel immediately and spread them out using a toothpick. After mixing, the mixture shall be processed within a maximum of 5 minutes to ensure optimum product flow. Please only use material from the same production batch to avoid variations in colour across the truck floor. Unpainted wooden boards must not have a moisture content higher than 8 to 12%. In this case, these boards must be treated with a primer using Körapox BS 85.

Step 3: Application of the covering layer

Once the levelling layer has dried, you can start applying the covering layer. You can use either Körapur 690 or Körapox BS 85, depending on the requirements and surface characteristics. The covering layer provides the final surface of the floor and ensures its resistance to mechanical stress.

Variant with Körapur 690

Apply Körapur 690 sealer, which contains quartz sand, over the cured Körapur 689 cover layer with a roller. This form of covering layer acquisition saves one step of the workflow and is characterised by an even appearance. Pour the sealer into the resin barrel, and allow it to drain completely. For the purpose of making the covering layer with Körapur 690, mix the resin and hardener vigorously in a 3 : 1 weight ratio, using a mixing device (approx. 400 rpm). The recommended processing temperature is 22°C.

Transfer the mixed mixture to another clean container and mix again. Only take the material to be processed from this second container. Then apply the mixed mixture to the surface treated with Körapur 689 with a foam roller, using the peahole roller type. The product consumption is about 600 to 800 ^g/m2, depending on the desired texture. Up to 10% Körasolv PR thinner can be added to adjust the texture.

After the surface has been treated, it can be passed over after 24 hours. Please only use material from the same production batch in order to avoid differences in colour on the truck floor.

Variant with Körapox BS 85

During the curing of the Körapur 689 topcoat, the granulate (corundum or quartz sand) is spread here and then topcoated with Körapox BS 85. This results in a very good durability. When the Körapox 689 cover layer is still curing, spread the appropriate corundum granulate here. Studded boots have proven to be suitable for crossing in this area. Then sweep the loose dust material out the following day. Pour the hardener into the resin barrel. For the purpose of making the covering layer with Körapox BS 85, mix the resin and the hardener vigorously in a 4 : 1 weight ratio, using a mixing device (approx. 400 rpm).

The recommended processing temperature is 22°C.

Transfer the mixed mixture to another clean container and mix again. Only take the material to be processed from this second container. Apply the mixed mixture over the entire surface with a roller, using a lambskin type roller. The product consumption is about 300 ^g/m2. Please only use material from the same production batch to avoid differences in colour across the truck floor.

Step 4: Drying and inspection

After the application of the covering layer, allow the floor to dry properly. The curing time may vary depending on the temperature and humidity of the environment. After curing, carefully inspect the entire floor surface. Correct any unevenness, bubbles or other imperfections.

Remember, it is important to follow all manufacturer's safety instructions on the MSDS when working with these products. Always wear appropriate protective equipment such as gloves and safety glasses. For example, gloves are recommended to ensure your safety when handling the products.

Differences between Körapur 690 and Körapox BS 85

When choosing the right product for your poured floor, it is important to understand the differences between the products. Here we look at two key products from Kömmerling - Körapur 690 and Körapox BS 85.

Körapur 690

Körapur 690 is a topcoat designed as a final layer for cast flooring in trucks, containers, vending vehicles, motorhomes, mobile homes and more. This product is particularly suitable for vehicles transporting fresh goods, meat, fish and for freezer vehicles where it has been tested down to -30°C. A special roller can be used to create a non-slip layer.

Körapox BS 85

Körapox BS 85 can be used as a final surface layer in a smooth finish or also as an anti-slip coating, using silica sand or corundum, in trucks, containers, sales vehicles, motorhomes, camping vehicles and more. This product is also suitable for vehicles transporting fresh goods, meat, fish and for freezer vehicles where it has been tested down to -30°C.

While both products are suitable for similar applications and have similar properties, the main difference between Körapur 690 and Körapox BS 85 lies in the base, which is polyurethane for Körapur and epoxy for Körapox. Körapox resists moisture very well and can therefore be used as an adhesive coating on wet floors before applying Körapur 689 levelling compound. The choice between Körapur 690 and Körapox BS 85 therefore depends on the specific requirements of the floor. Both products offer the high quality and durability you expect from Kömmerling products.

Summary

The Kömmerling floor system, which is supplied on the Czech and Slovak markets by TRANS-TECHNIK spol. s r.o., is suitable for various types of vehicles. It is very resistant to extreme temperatures and has a long service life. The floor treated with this system is easy to clean and is suitable for vehicles transporting, for example, fruit and vegetables, bakery products or even refrigerated products such as dairy products or meat. This floor system is also suitable for refrigerated vehicles transporting meat products and fish. For these special applications, the floor is designed with safety in mind and can therefore include a non-slip finish to reduce the risk of falls and accidents. The advantage of a poured floor system is its ease of application and professional aesthetic appearance, which can enhance the overall image of a company that applies this flooring to its vehicles.

If you are looking for a highly durable and reliable cast floor for your trucks, the Körapur and Korapox floor materials are an excellent choice. However, it is important to contact your authorised TRANS-TECHNIK dealer directly for more information on the specific features, installation options and pricing of this flooring system.

If you have any questions, please do not hesitate to contact TRANS-TECHNIK experts at +420 731 651 113 and +420 775 556 761, or email us at objednavky@trans-technik.cz. We are available Mon-Fri from 8:00 am to 4:00 pm.