How to maintain a sure footing01 August 2006

Industrial flooring is becoming smarter than ever, with manufacturers' research and development leading to a new era in floors that are faster to apply, more attractive and harder working. However, some basic factors need to be considered to ensure the right floors are specified, with the correct choice followed by good maintenance, vital to a successful project.

Specialist systems that deliver benefits such as anti-microbial performance or anti-static qualities have been on the market for a number of years, but they are being joined by other innovations.

Many manufacturers are pushing research and development to the fore to make industrial flooring so innovative. This means floors designed to perform to rigorous standards in a range of environments - such as hygienic systems in the food industry or chemical and oil resistant finishes in engineering factories - are also featuring benefits such as fast-track application qualities and aesthetics.

Whilst the speed of application might be a major driver in flooring choice, other factors need to be considered to get a true fit-for-purpose flooring system. Specific performance requirements are the key factors when choosing an effective system. This should be purpose designed to meet the service needs. A correctly specified resin system can provide up to 20 years' longevity, although, under the influence of economic choice, seven to 10 years may be more typical. While system thickness is not the only guide to these floors, it is a useful guide to anticipated life.

The amount of use a floor will be put under is an important point to consider. Low film thickness synthetic resin systems less than 1mm would normally only be installed in foot traffic areas in lighter industrial areas, whereas for heavy fork lift traffic a screed of up to 8mm or thicker might be needed. Medium thickness systems greater than 2mm would be used for heavy rolling loads, including fork truck traffic. For very heavy usage a system thickness of greater than 4mm would generally be used. FeRFA (The Resin Flooring Association) produces a comprehensive guide to the selection of synthetic resin floors, which is available at www.ferfa.org.uk. British Standards also offers guidance on the thickness of floor systems.

Safety is a crucial point. Slips and trips cost British industry thousands and thousands of pounds in injuries and the right floor can help cut the risk. In particular, wet areas need to be given careful consideration to ensure an effective flooring system is installed. One of the most important factors in these environments is slip-resistance. This is achieved by the introduction of a coarser texture, created by aggregates in the floor system.

Another factor in the flooring of wet areas is the product's ability to tolerate moisture and breakdown when exposed to constant damp conditions. For wet areas, floor finishes can be installed at levels between 1mm up to 8mm, depending on the clients' requirements.

Dry areas often have a lower requirement for slip resistance than wet areas and therefore smoother surface finishes can be used. The slip resistance of smooth finishes under dry conditions is generally excellent, but can depend on the type of footwear worn and dry surface contamination.

Cleanability is an important consideration. Thick polyurethane screeds and vinyl ester resins can stand up to steam cleaning, whereas not all types of resins and coating can. Another point: floor finishes are now available with anti-microbials, which can kill e-coli, listeria and even the MRSA bacterium.

Slip-resistance can have an effect on cleanability and the two factors need to be considered carefully as part of the specification process to ensure a floor is going to be fit for purpose.

If a floor becomes damaged, it becomes difficult to maintain (see table, above). However, resins and fine aggregates can be used that are designed to take impact, and create a robust and strong surface. This type of system is often called on for areas such as engineering workshops, where metal can fall to the ground and, without the right finish, chip the floor and expose the substrate. Increasing floor thickness and the use of resin screed formulations typically greater than 4mm will help to prolong the longevity of the floor and its aesthetics.

Similarly, chemicals can damage a floor, but resins can provide excellent resistance to their effects - in particular, inorganic and organic acids - and their tolerance is much higher than concrete. Synthetic polymers provide high levels of resistance to chemicals and, additionally, improve impact resistance, as well as offering an impervious barrier protecting the sub floor.

Some systems can also withstand various chemicals used in specialist industries. The ultimate chemical resistance of a resin floor is usually only achieved after full curing has taken place (typically 7 days), so it is important to protect the floor from spillage immediately after it has been laid.

Finally, to ensure the right choice in flooring, careful consideration needs to be given to very high or low temperatures.

Ultimately, by making the right choice and then adapting an appropriate maintenance routine, a new floor will provide a safe, attractive and workable platform underfoot. Get it wrong and costly repairs will need to be actioned and, in the worst-case situation, an ineffective floor might need to be completely replaced - a nightmare scenario in terms of cost and disruption for facilities managers, and others charged with ensuring a plant runs efficiently and effectively.

Mark Greaves is managing director of Flowcrete Group. For more information, visit: www.flowcrete.com

SOE

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