The deterioration and corrosion of concrete infrastructure have presented significant challenges in harsh operational environments such as sugar mills.

Corrosion protection, epoxy flooring and waterproofing company Verni Speciality Construction Products has, therefore, developed its Supaflor polyurethane heavy-duty (PU HD) screed and acid tile lining system, which Verni MD Vernon Botha says offers superior resistance to the specific conditions in sugar mills.

“The need for durable and efficient concrete protection solutions is evident, and sets the stage for Verni’s research and development (R&D) efforts in combatting the corrosive effects of molasses, the exposure to high temperatures and chemical agents that are some of the leading causes of concrete deterioration.”

Verni’s approach to addressing these operational challenges and needs involved extensive research into polyurethane formulations and acid-resistant materials to create a product that could offer the level of resistance required.

This exploratory phase was critical in laying the foundation for the development of effective corrosion protection systems, Botha adds.

With promising formulations identified, Verni then developed prototypes of the Supaflor PU HD polyurethane screed and acid tile lining systems, which were tested in real-world scenarios and, therefore, “instrumental in validating the prototypes’ durability, chemical and temperature resistance, and overall suitability for application in sugar mills”.

Insights gained from the testing phase resulted in fine-tuning and optimisation, which involved refining the product formulations and application techniques to enhance their performance and application efficiency.

Feedback from customer trials and field applications played a crucial role, Botha says, noting that this enabled Verni to make informed adjustments to meet the sugar industry’s specific requirements.

Consequently, the Supaflor PU HD screed can be applied to concrete surfaces laid only ten days prior, presenting a considerable advantage by minimising the duration of the application processes.

This time-saving attribute is particularly advantageous during nonharvesting seasons, facilitating efficient maintenance and repair activities within constrained time periods.

The adoption of Verni’s systems at sugar processing facilities leads to a multitude of long-term benefits, including enhanced operational efficiency, less downtime and a reduction in maintenance expenditure over time.

Moreover, customisation options for these systems allow for bespoke applications to align with the unique requirements and operational scales of sugar mills.

The “uninterrupted, anti-slip surface” of the Supaflor PU HD screed, coupled with its ease of maintenance, further assists in bolstering operational efficacy and augmenting safety measures in sugar processing environments, Botha says.

Further, Verni’s dual capacity as a material producer and specialised installer affords a holistic service proposition, inclusive of a unified guarantee, he notes.

The company’s expansive network of skilled and certified applicators throughout Africa also ensures that the delivery of installation services adheres to stringent quality standards.

Ongoing Research

Verni’s commitment to continuous improvement is reflected in its investing in ongoing R&D to enhance the performance of its corrosion protection systems.

“Future efforts will focus on developing new formulations that offer improved durability, environmental sustainability and cost effectiveness,” Botha adds, noting that supporting the sugar industry’s growth and sustainability is a key objective for the company.

With a record spanning more than two decades, Verni remains dedicated to providing technical support, training and consulting services to optimise corrosion protection strategies, he concludes.