Factory Floor Coating Systems
Engineered Flooring for Production & Process Areas
Why Do Factories Need Specialist Flooring?
Factory environments subject floors to concentrated point loads exceeding 3,000 PSI from machinery footings. Fork truck traffic generates 450,000 passes annually in typical facilities. Machine oil at 90°C hits concrete causing thermal shock failures within months. Add hydraulic fluid leaks, coolant spills requiring chemical resistant floor coatings, and metal swarf contamination. Standard epoxy delaminates after 6-8 months under these conditions.
Our industrial epoxy flooring systems use modified polyurethane with 65 Shore D hardness and 8,500 PSI compressive strength. The formulation includes aluminum oxide aggregates broadcast at 1.2kg/m² for abrasion resistance. Chemical resistance testing confirms zero degradation after 500-hour exposure to machine oils, MEK, toluene, and 30% sulfuric acid. Anti-static flooring variants achieve 10⁴-10⁶ ohms resistance for electronics manufacturing. Food-grade options meet ISO 22196 antimicrobial standards.
Installation methodology minimizes production impact. Diamond grinding removes laitance to ICRI CSP-3 profile. Primer application at 0.15kg/m² penetrates 2-3mm into substrate. Base coat applies at 2.5kg/m² using squeegee and spike roller. Broadcast aggregate embeds at 3kg/m² for heavy-duty zones. Top seal coat at 0.5kg/m² locks the system. Full cure allows forklift traffic after 16 hours at 20°C. Weekend installations return facilities to full operation Monday morning.
Factory Flooring Built for Your Industry
How Do We Ensure Production Continuity?
Production loss reaches £15,000 per hour in automotive assembly facilities. Phased installation methodology maintains 75% operational capacity throughout works. Section boundaries install temporary ramps maintaining forklift access. Night shift work from 22:00 to 06:00 allows day production continuity. MMA rapid-cure at 2-hour full strength enables immediate trafficking. Temperature-accelerated polyurethane cures to 25 N/mm² in 8 hours at 25°C substrate temperature.
Pre-installation testing determines exact preparation requirements. Schmidt hammer tests confirm concrete strength exceeds 25 N/mm². Moisture content measurement using calcium chloride method must show below 3 lbs/1000 sq ft. Oil contamination depth assessed via phenolphthalein indicator showing pH changes. Shot blasting achieves ICRI CSP-3 to CSP-5 profile depending on coating thickness. HEPA filtration maintains air quality below 0.15 mg/m³ respirable dust during preparation.
Safety demarcation integrates permanently into the resin matrix. Pedestrian routes use Signal Yellow RAL 1003 at 100mm width minimum. Forklift lanes marked with Traffic Blue RAL 5017 at 150mm width. Hazard zones incorporate retroreflective glass beads at 200g/m² for visibility. Emergency routes use photoluminescent pigments achieving 150 mcd/m² after 10 minutes activation. Line durability matches base floor system at 15+ years under traffic.
Which Factory Types Benefit Most?
Automotive factories require floors that resist hot oil, hydraulic fluid, and metal shavings while providing anti-fatigue properties for assembly line workers. We've installed specialized systems in BMW, Ford, and Toyota facilities that incorporate oil-resistant polyurethane topcoats with integrated comfort backing. These floors maintain their integrity despite constant forklift traffic and heavy component drops.
Food and beverage processing plants need hygienic, steam-cleanable surfaces that resist thermal shock. Our HACCP-compliant systems feature antimicrobial silver ion technology and coved skirting to eliminate bacteria harboring points. We use rapid-cure MMA resins that achieve full chemical resistance in 2 hours, perfect for facilities that can't afford extended shutdowns. These floors withstand daily steam cleaning at 80°C without deterioration.
Electronics and pharmaceutical factories demand controlled static dissipation and particle-free surfaces. Our conductive flooring systems maintain resistance below 10⁸ ohms while providing the durability to support heavy equipment. We install these systems in ISO-classified clean rooms using specialized techniques that prevent contamination. The seamless finish eliminates particle generation, helping maintain your clean room classification.
What's the Investment for Factory Flooring?
Factory flooring typically costs between £11-15 per m² per square meter for standard heavy-duty systems, with specialized solutions like ESD or extreme chemical resistance ranging up to £11-15 per m²/m². While this represents significant capital expenditure, our clients consistently report payback periods under 24 months through reduced maintenance, fewer accidents, and improved productivity.
Consider the hidden costs of poor flooring: workplace accidents averaging £11-15 per m²,000 per incident, production delays from floor repairs costing thousands per hour, and failed hygiene audits that can shut down food facilities. One pharmaceutical client calculated that our seamless flooring system saved them £11-15 per m²,000 annually in cleaning costs alone, not counting the avoided risk of contamination recalls.
We structure payment to match your budget cycles, offering options from single payment to 36-month spreading. Our detailed proposals include lifecycle cost analysis comparing our systems to alternatives, helping you build the business case for investment. We'll also connect you with other factories in your sector who've installed our flooring, so you can verify the returns firsthand.
Factory Floor Certifications
Factories That Trust Our Floors
View Some of Our Previous Work
Frequently Asked Questions
Heavy machinery areas require our ultra-heavy-duty systems, typically 9-12mm thick with compressive strength exceeding 80N/mm². We reinforce these areas with steel fiber mesh and use high-build epoxy mortars that distribute point loads. Expansion joints are cut and sealed with flexible polyurethane to accommodate thermal movement. We've successfully installed floors under 200-tonne presses that show no signs of damage after years of operation.
Temperature variation is common in factories, from freezers at -30°C to areas near furnaces exceeding 70°C. We install thermal shock resistant systems using flexible polyurethane technology that accommodates expansion without cracking. For extreme temperature zones, we use specialized resins that maintain flexibility across the entire temperature range. Transitions between temperature zones incorporate movement joints that prevent stress cracking.
Absolutely. We regularly install flooring around fixed machinery, conveyor systems, and production lines. Our teams use specialized cutting equipment to create precise terminations at equipment bases. We seal these edges with flexible sealant to prevent water ingress while allowing for equipment vibration. For sensitive equipment, we use low-vibration preparation methods and can even hand-apply systems in tight spaces.
Our factory floor systems typically last 15-20 years with proper maintenance. We've revisited installations from 2005 that still perform excellently. The key is selecting the right system for your specific environment and following our maintenance guidelines. Annual inspections help identify minor issues before they become problems. Many clients report their floors look nearly new after a decade of heavy use.
Our factory flooring systems comply with all relevant standards including HSE workplace regulations, COSHH requirements, and industry-specific standards like BRC for food factories. We provide complete documentation including slip resistance certificates, chemical resistance data, and fire rating reports. For food facilities, our systems meet HACCP requirements and we can provide declarations of conformity for food contact surfaces.
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