Our firm recently inspected the floor of a potassium nitrate fertilizer plant. Four large process vessels have leaked hot, concentrated nitric acid onto the floors. Several areas of the floor have deteriorated and, after repairing the floor, we want to install a protective overlay. We considered installing acid brick with furan mortar, but the floor cannot accommodate the 21_2-inch rise in elevation. Is there another overlay system we can use?
Another overlay system that is resistant to strong organic acids is potassium silicate. Potassium silicates can be installed about 11_2 inches thick and can perform in service temperatures as high as 2,000 F. Because potassium silicates are somewhat brittle, consider installing the system over an asphaltic membrane to protect the concrete should the overlay crack.