Seamless Resin Flooring
Jointless Self-Levelling Systems for Maximum Hygiene & Durability
Why Choose Seamless Over Traditional Flooring?
Joint-free flooring eliminates the primary failure point in traditional floor systems. Our seamless resin installations create monolithic surfaces spanning up to 5,000m² without joints, preventing water ingress, bacterial growth, and structural degradation. This continuous surface approach reduces maintenance costs by 70% compared to tiled alternatives over a 20-year period.
Self-levelling technology achieves tolerances within 3mm over 3 metres, exceeding SR2 flatness requirements. The fluid-applied system flows into every corner and crevice, creating perfectly level surfaces ideal for automated guided vehicles and high-bay racking installations. Material thickness ranges from 2mm to 6mm depending on traffic requirements and substrate conditions.
Seamless floors adapt to complex geometries including curves, slopes, and integrated drainage channels. We create continuous surfaces that flow from production areas through to loading bays without threshold strips or expansion joints. This uninterrupted surface eliminates trip hazards while facilitating efficient cleaning and material handling operations.
Seamless Flooring Solutions
How Are Seamless Floors Installed?
Installation begins with diamond grinding to achieve a CSP 2-3 surface profile. Moisture vapour testing determines if epoxy moisture barriers are required - we install these at 0.5mm thickness when substrate moisture exceeds 75% RH. Shot blasting removes laitance and opens the concrete pore structure for optimal resin penetration.
The primer application penetrates 1-2mm into prepared concrete, creating a molecular bond stronger than the substrate itself. We apply self-levelling resin at controlled temperatures between 15-25°C, using spiked rollers to release entrapped air. Flow rates and working time calculations ensure complete coverage before material begins to gel.
Curing occurs in stages - initial set within 8 hours allows light foot traffic, with full chemical resistance developing over 7 days. We maintain consistent temperature and humidity during cure to prevent surface defects. Final inspection includes thickness measurements at 25 points per 100m² and photographic documentation of the completed installation.
Which Industries Benefit from Seamless Systems?
Pharmaceutical manufacturers require seamless floors meeting FDA and EMA cleanroom standards. Our installations achieve surface roughness Ra values below 0.5 microns, preventing particle adhesion in Grade A/B environments. The monolithic surface withstands hydrogen peroxide vapour decontamination cycles without degradation, maintaining validated cleanliness levels between campaigns.
Food processors handling wet processes need seamless floors with integrated falls to drainage. We create 1.5-2% slopes within the self-levelling system, directing liquids to stainless steel channels cast into the resin. Anti-slip aggregates broadcast into the surface achieve R11-R12 ratings while maintaining cleanability - critical for SALSA and BRC certification.
Electronics assembly areas demand seamless conductive flooring preventing electrostatic discharge. Our systems incorporate carbon fibres throughout the resin matrix, achieving resistance values of 10⁴-10⁶ ohms. The continuous conductive surface eliminates dead spots common with tiled ESD flooring, protecting sensitive components across entire production floors.
How Do Seamless Floors Perform Long-Term?
Quality seamless installations maintain integrity for 15-20 years under constant industrial use. The absence of joints eliminates progressive failure mechanisms - there are no grout lines to crack or tiles to debond. Wear occurs uniformly across the surface, with high-traffic areas showing gradual thinning rather than catastrophic failure.
Chemical resistance remains constant throughout the floor's service life. Unlike coatings that rely on surface sealers, our seamless systems have consistent properties through their full thickness. Spillages of acids, alkalis, and solvents clean away without staining or degradation, maintaining appearance and performance decade after decade.
Refurbishment extends service life indefinitely through abrading and recoating worn surfaces. New resin bonds chemically with existing material, creating renewed seamless surfaces at 40% of replacement cost. This sustainable approach minimises disruption while maintaining the hygiene and durability benefits of jointless flooring throughout facility lifecycles.
Our Seamless Flooring Projects
Frequently Asked Questions
We regularly install seamless floors up to 5,000m² without joints. Larger areas are possible using flexible detail design at columns and doorways. The resin's flexibility accommodates normal building movement without cracking. Strategic saw cuts at 30-metre centres control any substrate movement while maintaining surface continuity.
Yes, seamless resin successfully overlays sound tile installations. We mechanically abrade tile surfaces and fill grout lines with flexible compound before applying primer. This creates a monolithic surface 4-5mm above existing floors. The process saves removal costs while eliminating all joints and contamination traps.
Localised repairs blend invisibly into seamless floors. We cut out damaged sections, prepare edges for adhesion, then pour matching resin. The repair material bonds chemically, restoring seamless integrity. Most repairs complete overnight, minimising operational disruption while maintaining hygiene standards.
Our seamless systems achieve SR2 flatness - within 3mm over 3 metres. For VNA racking requiring SR1 Super Flat specifications, we use laser-guided screeding achieving 1.5mm tolerance. The self-levelling properties naturally eliminate minor substrate irregularities, creating surfaces suitable for robotic operations.
Actually, seamless floors stay cleaner than tiled alternatives. Without grout lines to trap dirt, contaminants sit on the surface for easy removal. We incorporate colour flakes or patterns that disguise minor soiling between cleaning cycles. The uniform surface allows efficient mechanical scrubbing without catching on joints.
Eliminate Joints, Maximise Performance
Professional seamless flooring with 15-year performance guarantees.