Industrial Flooring Solutions
ACC Flooring have been installing industrial flooring solutions to a wide range of industries for over 30 years. An industrial resin flooring has numerous characteristics including performance, durability, hygiene and an extensive colour range. Epoxy and polyurethane resin flooring and wall solutions offer the client a tailor-made industrial resin flooring package that can be applied in a vast range of industries and workplace environments.
Our industrial flooring solutions can be customised to meet any requirements. Resin flooring can be applied to:
If you have any questions or require more information about our industrial resin flooring solutions, please get in touch.
Types of Industrial Flooring Solutions
Epoxy floor coatings, FeRFA Type 1 – 3 classifications are for light to medium duty industrial flooring environments. Applied in two or more coats at a typical thickness of 1mm and offering a life expectancy of 5 – 7 years, they are ideal for chemical storage, plant rooms, storage and packing areas, workshops and warehousing. They offer limited impact resistance and good chemical resistance. A non-slip aggregate can be introduced between coats to provide a slip-resistant profile that when tested will give a ptv of ≥36.
FeRFA Type 4 classification Multi-layer industrial flooring types for medium to heavy duty locations are typically applied at ˃2mm. They are an aggregate dressed system with a decorative appearance, often described as a sandwich system, offering a life expectancy of 8 years. They have limited impact resistance with good chemical resistance and are ideal for circulation areas, reception areas and toilets.
They also provide a cost effective solution against traditional soft floor coverings such as vinyl, carpets and carpet tiles.
A self-levelling or self-smoothing epoxy industrial flooring solution with a life expectancy of 10 years is designed for medium to heavy duty traffic. Applied at 2mm to 3mm this FeRFA Type 5 classification is perfect for warehousing, vehicle workshops, pharmaceutical, packing and storage areas. A 3mm system is also ideal for high traffic and wheeled traffic areas.
With a high gloss finish, and offering increased hygiene characteristics, this industrial flooring solution also benefits from a static-dissipative variant which when tested to BS 2050 give a typical value of 5x 104-2×106 ohms and is optimal for control rooms, ICT areas and electronic assembly.
FeRFA Types 1 to 5 are easy to maintain by wash and vacuum dry method.
FeRFA Type 6 classification includes epoxy resin screed flooring. Installed at ˃4mm with a 10 – 15 year life expectancy and a slip-resistant variant give a ptv of ≥40. This highly decorative quartz product offers the perfect choice for laboratories, pharmaceutical, food and drinks packing, clean rooms, production areas and warehousing.
Industrial flooring contractors find this range of products ideal for medium to heavy duty workspaces with moderate impact and chemical resistance. For where there are electronic sensitive environments and equipment a static-dissipative option is measured in accordance with BS 2050.
Heavy duty flowable industrial resin flooring is classified as FeRFA type 7. Installed at 4 – 6mm with the added advantage of slip resistant divergences offering a ptv of ≥36. This industrial flooring solution also exhibits good impact resistance and excellent chemical resistance. A 10 year life expectancy makes it the perfect choice for food and drink production, production and packing areas, laboratories and clean rooms.
For the ultimate industrial floor covering, a heavy duty polyurethane screed installed at 6 – 9mm provides unsurpassable characteristics in performance. With excellent chemical and impact resistance and a slip resistance ptv of ≥50 together with a 15 year life expectancy, this FeRFA Type 8 product classification is unmatched as a comprehensive industrial flooring solution.
FeRFA Types 6 to 8 are easy to maintain by low pressure washer/scrubber dryer methods.
For a full guide of FeRFA types and descriptions view our Guide to the FeRFA Resin Flooring Association page. Of go to their website at www.ferfa.org.uk.
We take a look at some of the most common industrial sectors:
With ramps, rotary lifts, pits and rolling roads in heavy traffic areas, industrial flooring solutions in the automotive sector need to be fit for purpose but also provide a safe working environment by the use of high visibility demarcation in the form of line markings and designated walkways.
Car park waterproof decking systems brighten any multi storey or underground car park utilising different colours to designated areas such as traffic routes including directional arrows and hatchings, parking bays, pedestrian walkways and crossings.
Deckmaster are one of the UK’s leading manufacturers of car park decking systems for both internal and external areas.
Industrial resin flooring types in the automotive sector can also be decorative. Acrylic flake systems can provide a breathtaking backdrop to any high class vehicle.
The biggest fear in the chemical industry is loss of containment to either primary or secondary containment areas or environments where severe chemical attack is a concern.
Chemical bunds require not just a heavy duty polyurethane screed to the flooring area but also a wall render at the transition of the floor and walls to any coving detail which can them be coated with a water based polyurethane grout. Engineering brickwork can then be protected with highly chemical resistant polyurethane coating systems.
Take a look at our Chemical Plant Case Study.
Durability, impact and abrasion resistance are three of the main characteristics of an industrial floor covering for such a demanding environment. Slip-resistant properties will also enhance both the features of industrial resin flooring in addition to providing a safer working environment.
Most industrial flooring contractors would recommend the installation of a heavy duty polyurethane screed which is not only seamless and hygienic but encapsulates all the requirements for engineering flooring. The product which has a natural matt finish can be heightened with a gloss seal coat to improve and ease the cleaning and maintenance process.
A heavy duty polyurethane screed has a life expectancy of 15 – 20 years and is the ideal industrial flooring solution for demanding areas.
Take a look at our Engineering Workshop Case Study.
For further information have a read of Altros 6mm Slip Resistant Textured Surface.
Food and Beverage
Heavy duty polyurethane screed installed at either 6mm or 9mm is the ultimate industrial resin flooring solution for the food and beverage industry. These trowel applied types of industrial flooring can be laid on concrete and polymer modified cementitious screeds. With a seamless matt finish and slip resistant profile the product features include:
- Stable to steam cleaning and hot water exposure at a thickness of 9mm
- Very high chemical resistance to aggressive chemicals
- High abrasion resistance
- Excellent thermal shock resistance
- Good cleanability
- Meets the European Directive on the Hygiene of Food Stuffs (93/43/EEC)
- 15 – 20 years life expectancy
Typical areas of use include:
- Food processing
- Abattoirs and meat processing plants
- Commercial kitchens
- Storage areas
Take a look at the Resdev Food Industry Brochure for more information.
Various types of industrial flooring would be suitable for the packaging sector from high build epoxy coatings, self-levelling, high gloss, epoxy flowable industrial resin flooring, and multi-layer and decorative quartz systems to heavy duty polyurethane screeds. Low odour, solvent free, non-dusting and durable solutions are available and with a varying life expectancy from 7 – 20 years, easy to clean properties, industrial resin flooring can deliver the optimum product for any environment including both wet and dry production areas, circulation areas, changing rooms and showers.
High visibility demarcation areas including walkways, zebra crossings and fire exits can be installed to provide a safe working environment for employees and visitors.
Industrial flooring contractors installing industrial flooring solutions into the pharmaceutical sector will offer a comprehensive range of fit for purpose products which would include high build epoxy coatings, decorative quartz systems and heavy duty polyurethane screeds. These products are ideal for wet and dry production areas, laboratories and clean rooms and packing areas. In addition some areas within a pharmaceutical facility would need a static dissipative industrial resin solution.
Altro Resins offers a 4mm static dissipative variant in their Altro Screed Quartz range and a 3mm static dissipative variant in their Altro Flow range which is measured in accordance with test method BS 2050.
Resdev also offer a small range of static dissipative products including:
All their products are compliant with BS 2050.
FeRFA provide a guide for static dissipative industrial resin flooring.
Warehouses due to their nature are heavy traffic environments. With constant fork lift truck and other vehicle movements in addition to foot traffic, industrial resin floor coverings offer dust free, durable solutions which are cost effective and fit for purpose.
Most warehouse flooring will be installed in an epoxy coating, FeRFA types 2 and 3. These systems will provide 5 – 7 years life expectancy. Slip resistant options can be installed in doorways to offer some resistance to tyres in wet weather conditions.
FeRFA Type 4 Grip systems are ideal for areas of constant fork lift use. Industrial flooring contractors will install a heavy duty three component flexible binder which when scattered with natural or synthetic aggregates creates a slip resistant profiled surface.
These systems are hard wearing, tough and slightly flexible with rapid installation to minimise downtime.
High visibility walkways, zebra crossings and other forms of demarcation can offer safe working conditions for all employees.
Cleaning and Maintenance
Resin floors are tough resilient systems, however, for the performance characteristics of the floor to be maintained, an appropriate cleaning regime should be agreed in advance.
The cleaning regime will itself be determined by a number of factors; the type of resin flooring installed, the type of frequency of traffic, the degree and type of soiling and specific hygiene requirements.
If you are interested, here’s a FeRFA Publication on cleaning and maintaining an industrial resin floor.
Recommended cleaning methods
- Wash and vacuum dry – FeRFA Types 1, 2, 3, 4 (excluding Grip systems) and 5
- Scrubber Dryer – FeRFA Types 4 (Grip systems only), 6 and 7.
- Low pressure water/scrubber dryer – FeRFA Type 8
ACC Flooring is legally registered to remove waste generated from all sites and hold all the requirement waste transfer licences. ACC Flooring can also provide monthly reports so all clients can see exactly what products and quantities are being recycled.
At a recently completed project at Sheffield Teaching Hospital, 100% of the waste produced was recycled. Take a look at the Case Study for this project.
In the food and beverage industry where hygiene is paramount, drainage systems can be installed. This may involve the installation of a cementitious screed to falls to ensure that the water is directed into the drains. Blucher stainless steel drainage systems are ideal for this type of environment and can also include traps and baskets. A specialist contractor will be needed to cut the concrete to the desired length, depth and width. The channel can then be set and the concrete allowed curing prior installation of the industrial resin flooring.
Here’s a case study for a food preparation company we completed in March 2018.
Sub Floor Screeds
FeRFA provide a comprehensive guide for all types of sub floor screeds.
Altro Resins offer a polymer modified cementitious systems which supports a range of floor finishes including resin and vinyl industrial flooring types. Altro Pol is designed to enhance the physical properties of cement based floor screeds and repair compounds. It improves flexural strength, impact and abrasion resistance. Check out Altro’s Technical Data Sheet.
Flowcrete offer a wide range of bonded and unbonded screed products under their Isocrete banner.
Their screed offer also includes Flowscreed Industrial Top which is a fast drying cement based, pump applied floor topping for fast track renovation of concrete floors.
Damp Proof Membranes
Liquid applied, solvent and water free epoxy damp proof membranes are designed to withstand moisture vapour from the substrate. They are ideal for using on fast-track building projects or refurbishment schemes.
A damp proof membrane is a single coat application providing protection across a range of moisture contents from relative humidity of more than 75% to 100%. They are easy to apply and provide excellent adhesion under adverse conditions.
There is a range of concrete flooring repair products available from Resdev ideal for concrete, polymer modified and cementitious screeds.
- Pumabulk is resin rich granite reinforced; trowel applied polyurethane repair mortar for use as an underlayment or infill and can be used to form falls or ramps prior to the installation of the industrial resin flooring.
- Pumaintain Floor Repair is a low odour polyurethane concrete which has been specifically designed to provide an easy to use floor patching compound with excellent physical properties.
- Pumaintain Joint Repair is a low odour polyurethane concrete which has been specifically designed to repair joint arrises in concrete floor slabs and will withstand continuous wear from fork lift trucks and wheeled traffic.
Both Pumaintain Floor Repair and Joint Repair will cure at temperatures of below 5°C unlike epoxy mortar compounds.
Coving detail can be formed usually from 100mm – 150mm high to provide a hygienic transition from the resin flooring system to the wall systems this could include both cladding and resin.
Altro Screed 3mm standard variant can be applied to vertical surfaces as a wall render for fully-tanked wet rooms or seclusion suite locations.
Resin systems can also be applied to chemical bunds to ensure loss of containment. A polyurethane mortar can be formed to coving, plinths and bases, drain linings and bunds. A water based polyurethane grout is then applied as a seal to provide a mottled matt finish.
To engineering brickwork a chemical resistant polyurethane coating can be applied in either a gloss, matt or silk finish. The cured coating has excellent abrasion and chemical resistance and also excellent weathering properties.