Heavy-Duty Industrial Flooring
Ultra-Thick Systems for Extreme Load & Impact Resistance
Why Do Standard Floors Fail Under Heavy Industrial Use?
Standard concrete floors fail under heavy industrial epoxy flooring requirements within 6-18 months of installation. Point loads from 5-tonne forklifts create 35N/mm² stress concentrations, pallet drops generate 100kN impact forces, and HGV traffic applies 10N/mm² continuous pressure. These stresses cause spalling, cracking, and substrate failure costing £50-80 per m² in repairs annually.
Heavy-duty resin systems incorporate 6-12mm buildup achieving 80-120N/mm² compressive strength. Steel fibre reinforcement at 35kg/m³ provides tensile strength of 8N/mm², while polyurethane underlays absorb 40% impact energy. Armoured joints with 6mm steel angles accommodate 5mm thermal movement under 50-tonne wheel loads without edge failure.
Performance testing validates specifications through accelerated wear protocols. Systems endure 15,000 daily forklift passes showing <0.1mm annual wear, thermal cycling -30°C to +70°C causes zero delamination, chemical resistance covers pH 2-13 exposure. Load distribution calculations confirm 25-year structural integrity under specified traffic patterns.
Heavy-Duty Flooring System Options
How Do We Engineer Floors for Extreme Loads?
Substrate analysis employs GPR scanning to 300mm depth identifying voids >10mm diameter. Core testing determines in-situ strength using BS EN 12504 protocols targeting 35N/mm² minimum. FEA modelling calculates stress distribution for actual equipment including 12-tonne reach trucks and 40-tonne HGVs at specified traffic densities.
Build-up sequences follow engineered specifications. Penetrating primers achieve 3-5mm depth consolidating weak substrate to 25N/mm² minimum. Steel fibre screed at 40-60mm thickness incorporates 35kg/m³ fibres providing flexural strength of 5N/mm². Broadcast layers use 3-5kg/m² angular quartz creating mechanical key. Aluminium oxide topcoats at 2mm provide Taber wear index <0.02mm/1000 cycles.
Joint engineering accommodates building dynamics. Armoured edges using L-shaped steel profiles 75x75x6mm prevent spalling under 10-tonne wheel loads. Induced joints at 6-metre centres control shrinkage cracking through 1/3 depth saw cuts. Isolation joints incorporate 20mm compressible foam allowing ±10mm movement. Detail specification prevents progressive failure mechanisms common in standard installations.
What Impact and Abrasion Resistance Can You Expect?
Abrasion resistance testing per ASTM D4060 demonstrates 0.015-0.02mm loss per 1,000 Taber cycles using H-22 wheels. Impact tests following BS 8204-2 achieve Class A rating withstanding 20Nm drops without visible damage. Indentation resistance exceeds 150N/mm² with <0.5mm permanent set under sustained loading for 24 hours at 23°C.
Field performance data from 500+ installations validates laboratory results. Automotive facilities moving 2-tonne dies show 0.3mm wear after 5 years equating to 0.06mm annually. Distribution centres with 5,000 daily pallet movements maintain SR2 surface regularity after 10 years. Steel service centres dragging 20mm plates cause surface scratching <0.1mm depth, below critical wear thresholds.
Localised repair protocols extend service life beyond 25 years. Traffic lane refurbishment at 10-12 year intervals costs £15-20/m² versus £60-80/m² for complete replacement. Patch repairs using matched chemistry achieve 95% original strength within 24 hours. Preventive maintenance programmes identify wear patterns through annual thickness measurements, scheduling intervention before substrate exposure.
Which Industries Demand Heavy-Duty Flooring?
Automotive production lines impose 10-15 tonne point loads from robotic cells and transfer presses. Vibration isolation layers reduce transmitted energy by 60% protecting AGV guidance systems requiring ±2mm tolerance. Chemical resistance specifications cover glycol-based coolants at 90°C, mineral oils at 150°C, and battery acid at 37% concentration. Floor flatness maintains FM2 classification essential for 0.1mm assembly tolerances.
Cross-docking facilities process 500-1,000 vehicle movements daily requiring minimal maintenance windows. MMA rapid-cure systems achieve C35 strength in 4 hours enabling weekend installation of 2,000m². Service life exceeds 20 years at 0.05mm annual wear rates. Anti-static specifications maintain 10⁴-10⁶ ohms protecting electronic goods worth £10-50 million daily. Thermoplastic line marking withstands 10,000 wheel passes before refresh.
Waste transfer stations expose floors to leachate at pH 3.8-11.5, 95% humidity, and 100-tonne compactor vehicles. Specialised methane-resistant resins prevent degradation from landfill gas exposure. Surface profiles achieve R12 slip resistance with organic contamination present. Impact tolerance handles 5-tonne grab bucket drops from 3 metres. EA-compliant sealed surfaces prevent groundwater contamination meeting Pollution Prevention Guidelines.
View Some of Our Previous Work
Frequently Asked Questions
Thickness specifications match load requirements precisely. 3-5 tonne forklifts at 200 movements daily require 6mm systems. Continuous operations with 7-tonne trucks need 8-9mm applications. HGV traffic exceeding 30 tonnes demands 10-12mm minimum thickness. Calculations factor wheel material (polyurethane vs steel), contact area (150-300cm²), and frequency (movements per hour) determining optimal buildup without over-specification.
Standard systems withstand 70°C continuous and 90°C intermittent exposure through modified polymer chemistry. High-temperature specifications using novolac epoxy handle 150°C constant exposure with 200°C spike tolerance. Reflective aluminium pigments reduce surface temperature by 15-20°C. Thermal barrier undercoats provide additional insulation. Foundries routinely position 180°C castings directly on treated surfaces showing zero thermal damage after 10,000 cycles.
Surface regularity achieves SR1 classification with 3mm maximum deviation over 3-metre straightedge. VNA operations receive FM1 superflat specifications using laser-guided screeding at ±1.5mm over 3m. Self-levelling underlayments at 3-50mm thickness correct substrate irregularities. Finished tolerances support automated systems requiring ±2mm, high-bay racking at 30m height, and precision machinery demanding 0.5mm/m flatness.
Chemical resistance extends beyond mechanical properties. Standard formulations resist mineral oils indefinitely, diesel/petrol for 365 days, and hydraulic fluids at operating temperatures. Vinyl ester systems withstand 98% sulphuric acid, 50% sodium hydroxide, and concentrated solvents including MEK and xylene. Bunded zones incorporate 150mm containment walls with chemically welded joints. Resistance matrices document 200+ chemicals with immersion times and concentration limits.
Warranty coverage reflects engineering confidence. Materials and workmanship carry 10-year minimum protection with insurance backing through Lloyds of London. Wear warranties guarantee <0.2mm annual degradation for specified traffic - typically 15-20 years coverage. Structural warranties extend 25 years on substrates exceeding 30N/mm². Optional annual inspections at £500-800 extend coverage by 5 years. Claims history shows 0.3% warranty activation rate across 500,000m² installed.
Engineer Your Floor for Decades of Heavy Use
Don't let floor failure stop production. Invest in genuine heavy-duty solutions.