Polyurethane Flooring Systems
Ultimate Performance Flooring for Extreme Industrial Environments
Why Choose Polyurethane for Demanding Environments?
Food processing flooring faces a specific challenge. Floors endure 120°C steam cleaning at night, then freezer truck traffic by morning. Standard epoxy cracks within months under this thermal assault. Polyurethane handles these temperature swings daily for 15-20 years without failure.
We've installed polyurethane systems in 200+ London facilities since 2010. The material tolerates conditions from -40°C in blast freezers to +120°C during steam sanitization. Impact tests show 4mm polyurethane absorbs drops from 2-metre heights that shatter 6mm epoxy.
Breweries particularly benefit from polyurethane's chemical resistant floor coatings performance. Hot wort spills at 100°C, caustic CIP solutions, and acidic waste all attack concrete. Our polyurethane installations from 2015 still perform flawlessly despite this daily chemical exposure. The seamless resin flooring eliminates bacterial harboring points required for hygiene certification.
What Makes Polyurethane Flooring Superior?
Thermal Shock Resistance
Tested from -40°C freezer to 120°C steam without cracking. Handles daily temperature cycling that destroys rigid floors.
Chemical Immunity
pH range 2-12 tolerance verified. Resists 50% sulphuric acid, sodium hydroxide, and organic solvents for 20+ years.
Impact Absorption
6mm polyurethane absorbs 2kg drops from 2 metres. Workers report 35% less fatigue versus concrete floors.
Seamless Hygiene
Zero joints from floor to 150mm cove height. Bacteria counts stay below 10 CFU/cm² after standard cleaning.
Industrial-Strength Flooring That Lasts Decades
How Do We Install Polyurethane Flooring Systems?
Shot blasting creates a CSP-3 to CSP-5 surface profile on existing concrete. We test moisture content below 5% using calcium chloride tests. Cracks wider than 2mm receive rigid epoxy repair compound rated for 50 N/mm² compression.
Polyurethane mixes at a precise 4:1 ratio using calibrated pumps. Application thickness ranges from 4mm for light duty to 9mm for heavy forklift areas. The material flows at 23°C for 15 minutes, requiring experienced teams working in coordinated sections.
Temperature affects cure speed significantly. At 20°C, foot traffic resumes after 12 hours. Full chemical resistance develops within 72 hours. Winter installations below 10°C require heated tents or extended cure schedules. We've completed 500m² weekend installations allowing Monday production startup.
Polyurethane Flooring Investment Levels
Standard Polyurethane
- 4-6mm thickness
- Standard colour range
- Smooth or textured finish
- 10-year warranty
- 72-hour full cure
Heavy-Duty System
- 6-9mm thickness
- Enhanced impact resistance
- Integral cove base included
- 15-year warranty
- Anti-slip aggregates
Fast-Track Installation
- Rapid cure formula
- 12-hour return to service
- Weekend installation
- Minimal production loss
- 15-year warranty
View Some of Our Previous Work
Frequently Asked Questions
Epoxy costs £45-60 per m² and handles normal industrial conditions well. Polyurethane at £70-100 per m² survives conditions that destroy epoxy within months. Temperature swings crack epoxy at the substrate bond. Heavy impacts leave permanent dents. Polyurethane flexes with thermal movement and rebounds from impacts. The 30% price premium pays back through 15-year service life versus epoxy's 7-10 years in harsh environments.
We test samples at 120°C steam for 1000 hours without failure. Daily 70°C washdowns pose no threat. The polymer structure remains stable up to 150°C, well above typical steam cleaning temperatures. Food plants using 15-bar steam at 120°C report zero degradation after 10 years. The material stays bonded even with thermal shock from ice to steam within seconds.
3-tonne forklifts require minimum 6mm thickness. 5-tonne units need 9mm systems. Point loads reach 50 N/mm² under turning wheels. Polyurethane distributes this stress through elastic deformation rather than cracking. Silicon carbide aggregate in traffic lanes adds 40% wear resistance. Distribution centers with 200 daily forklift movements show 0.5mm wear after 5 years on 9mm systems.
Tests at -40°C show polyurethane retains 85% flexibility versus room temperature. Epoxy becomes brittle below -10°C. Thermal cycling between -30°C storage and +20°C loading docks creates 50°C temperature differentials. Polyurethane accommodates the 3mm/metre thermal movement without cracking. Aluminum oxide broadcast at 0.5kg/m² maintains R11 slip resistance on icy surfaces.
Standard formulations reach 70% strength at 24 hours, allowing foot traffic and light trolleys. Full 85 N/mm² strength develops by 72 hours. Fast-cure MF systems achieve working strength in 12 hours at 20°C. We section 2000m² facilities into 500m² zones, maintaining 75% operational capacity during installation. Friday night to Monday morning installations minimize revenue impact.
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