How to Find the Best Industrial Flooring

THE BEST FLOORING FOR HIGH TRAFFIC AREAS

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A 'high traffic area' means, quite simply, an area that is frequently traveled by foot or by vehicle. A grocery store filled with walking customers and rolling shopping carts, an auto service shop with walking technicians and driving cars, and a restaurant kitchen filled with rushing staff are all examples of high traffic areas.

Abrasion Resistance

It is important for high traffic flooring to resist abrasion. Hard wearing industrial flooring should be able to hold up under years of traffic without grooves or wear patterns appearing along frequently traveled paths. These wear patterns are more than unsightly; as the surface layer of a floor wears away, the floor may become susceptible to all those things it was supposed to resist, like water and chemicals.

Thin coatings are not well suited to high traffic areas for this reason. For long-term durability, companies should look to thick or full-body floor coverings. A full-body flooring material has the same density, hardness, color, and resilience throughout. Surface scratches, scrapes, or wear patterns on full-body flooring are less visible and do not affect the resistant properties of the floor.

Slip Resistance

Slip resistance is an important consideration in areas with high foot traffic. Companies that cut corners on this feature may find themselves on the wrong end of expensive lawsuits or workers' compensation claims after a slip-and-fall accident.

The amount of slip resistance needed depends on the environment. The floor in a car wash, for example, is virtually always covered by slippery substances like water, soap, and wax, while bakery floors stay mostly dry. When choosing a flooring surface, the bakery could safely opt for a lower profile than the car wash.

Industrial anti-slip flooring typically relies on either texture or grit to increase traction. Texture is found in flooring surfaces like dry-pressed tile. At the time of manufacture, tiles are pressed into molds that leave a textured impression on their surface. The deeper the impression, the higher the tile's slip resistance.

Liquid flooring options rely upon grit to provide slip resistance. At some point after the floor coating has been poured, a fine, gritty substance is scattered across the top. As the floor cures, this grit becomes a permanent part of the surface. A good flooring contractor will be careful to spread the grit evenly across the floor to avoid unexpected slick spots. If the coating begins to peel, wear off, or is otherwise compromised, it is important to repair as soon as possible, as the underlying surface will not be slip resistant.

A floor's cleanability is directly related to its slip resistance. The same texture or roughness that provides traction underfoot creates small nooks and crannies where dirt can settle. The more slip resistant the floor, the deeper these crannies are, making them difficult to clean with conventional methods like mopping. Most brands of industrial tile, including Argelith, have a baked-on finish that reduces friction and enhances cleanability. For easiest cleaning, companies should choose the lowest profile that provides the required level of grip. A floor scrubber equipped with a vacuum is an effective way to remove soil from a slip resistant floor.

DO I NEED CORROSION RESISTANT FLOORING?

All industrial flooring begins with a concrete subfloor. Industrial floor coverings come into play because most concrete, on its own, is porous and is not chemical resistant.

Chemical reactions damage a floor's integrity. In some cases, the reaction is immediate and visible in the form of a stain. Concrete corrodes quickly under chemical attack, becoming dusty, cracked and pitted.

In many cases, however, chemical attack is slow and insidious, invisibly weakening the floor covering and allowing water, chemicals, and microbes access to the vulnerable subfloor.

It is vital facility designers know exactly what substances are being used in each area of the facility and how they react with the elements that make up the floor. A bakery, for example, may use acidic substances like sugar and fruit juice; alkaline substances like salt; and oily substances like food oils and nuts. The person or team specifying flooring for the bakery must understand how each of these ingredients will react with the flooring material being considered.

WATERPROOF FLOOR OPTIONS

Water is the natural enemy of concrete. As a concrete floor absorbs moisture, it creates a lush breeding ground for mold and microbes. Iron rebar deep in the concrete corrodes under the damp conditions. As the water freezes and thaws, its expansion and contraction is too much for the concrete to bear, causing the floor to buckle and crack.

Chemical floor coatings rely upon sealants or water-resistant topcoats to protect the subfloor from moisture damage. These sealants can be effective as long as they are carefully monitored for cracks and wear and are reapplied periodically. The frequency of reapplication depends on a variety of factors.

While glazed tile also uses a surface coating to repel moisture, vitrified ceramic relies upon its density to resist water damage. The manufacture of pressed vitrified tiles involves a series of steps, each of which presses the molecules in the tile closer and closer together. By the time an Argelith fully vitrified tile leaves the factory, there is not enough space between the ceramic molecules to allow water to penetrate, resulting in a permanent absorption rate of less than 0.1 percent.

When tiling areas with heavy or frequent water exposure, a facility designer must be careful to specify water-resistant adhesive and grout. Fully vitrified tile laid with an epoxy grout is water resistant, but just like a full epoxy floor, the epoxy grout may eventually require reapplication. A water-resistant adhesive prevents any moisture that seeps through a damaged grout joint from affecting the subfloor beneath.

Wet areas like car washes or beverage production lines can be further protected with the addition of wall tile and cove base. Wall tile, whether vitrified or glazed, protects the wall in the splash zone of wet applications. Cove base joins the floor and the wall on a curve, rather than a 90-degree angle. This allows water to roll down the curve and onto the floor, which should be sloped to a drain, rather than settling into the joint between wall and floor.

Drains are another important aspect of flooring in a wet industrial zone. Like the flooring itself, drains should be made of a material that will not react or corrode under exposure to the substances used in the industry. Floors in wet areas should be sloped to drains and laid in such a way that water flows freely to the drain rather than puddling or traveling in channels.

CHOOSING A FLOORING CONTRACTOR

A successful industrial flooring installation is not a do-it-yourself project.

Cash-strapped business owners may think flooring their facility is akin to painting their garage floor or tiling the bathroom in their home. This naivete is a mistake that could cost the business dearly when the amateur flooring job eventually fails.

An effective industrial floor has at least four parts: the properly prepped subfloor; the underlayment, base coat, or mudbed; the main body of the floor; and a topcoat or grout. In some cases, additional layers like slipsheets or moisture vapor transmission barriers may be required. Failure in any one of these levels could lead to failure and expensive remediation of the entire floor.

A business that hesitates to spend on installation will almost certainly be forced to spend on remediation.

When choosing a flooring installer, make sure the chosen contractor is experienced with your industry. Experienced installers should be able to provide references within the same industry as the prospective client. In an ideal scenario, you should also be able to visit these references and see the installation firsthand.

A qualified installer will be familiar with the demands of the industry and with any pertinent regulations or requirements, such as USDA or FDA regulations for food production facilities.

Qualified installers have the experience and education to place expansion joints in the optimum locations to prevent cracking and understand the ideal environmental conditions under which to lay the floor.

A reputable installer will have access to materials and tools that may not be readily available at do-it-yourself stores. He or she should be able to tell the prospective client what products are recommended for the floor and why. The experienced installer will understand how each element of the floor works with the others and can ensure each product used in the installation is compatible with the others.

Are you interested in learning more about heavy duty industrial flooring? Contact us today to secure an expert consultation!

ENVIRONMENTALLY SAFE FLOORING

While a building material's impact on health and the environment may not be your first consideration, firms are reporting it as increasingly relevant.

Some building materials emit chemical fumes or volatile organic compounds (VOCs). Some people have a heightened sensitivity to these products and may find it difficult to work around them. Facilities that manufacture products for consumption, like food and pharmaceuticals, may also have concerns about product contamination from abraded particles of these materials. A product's recyclability at the end of its lifespan and the environmental impact of its manufacture are also features to consider when attempting to choose green building materials.

WHEN TO OPT FOR INDUSTRIAL TILE

Argelith's fully vitrified industrial tile is a hard-wearing option for facilities with demanding environments. The strength and density of the tile supports heavy weight, and when properly installed distributes the weight evenly across a wide area of the subfloor. The hardening process the tiles undergo results in a surface that meets or exceeds industry standards in abrasion resistance, and the tiles are a full-body floor covering, making them a durable choice in high traffic areas.

Argelith's fully vitrified tiles have a water absorption rate of less than 0.1%, making them suitable for wet environments when installed with a water-resistant grout and adhesive. Hexalith tiles are designed to slope to drains at any angle. The tiles are butt jointed, which reduces dependence on grout and results in small, flat grout lines that do not channel water.

Tiles are available in an assortment of slip resistant profiles. Because the profile relies upon texture, not grit, soil is less likely to cling to the surface.

Ceramic is a natural, chemically stable substance that does not react to chemical exposure. It heats and cools slowly and evenly, and when installed with appropriate expansion joints can be used under boilers, in deep freezers, or at any temperature in between. HACCP-certified ceramic is naturally hygienic and provides no refuge for microbial contaminants. At the end of its useful life, it can be crushed into recycled aggregate and used in future building projects.

Industries well suited to industrial tile floors include:

• Auto service and oil change shops

• Car washes

• Breweries, wineries and distilleries

• Soft drink, juice, and ready-to-drink beverage bottlers

• Bakeries and processed food manufacturers

• Slaughterhouses and meat packing facilities

• Dairies

• Pharmaceutical and health supplement laboratories

• Cannabis growing facilities

• Chemical manufacturers

Click here for your free downloadable checklist of questions to ask when choosing industrial flooring.

Industrial flooring is one of the most important parts of any industrial setting. Workers need to be able to rely on it if they plan to get any work done efficiently and safely. The last thing they need is to slip and fall or spark a fire while on the job.

However, there are many different floor coating types available to building managers. Some offer more durability and will last longer when paired with heavy machinery. Others are non-static and slip-resistant, which may be more important in other industries.

Here is your guide to industrial flooring solutions for your next flooring project.

Concrete Flooring

Concrete flooring is one of the most affordable industrial flooring options for your workspace. A polished concrete floor is also very durable, as it can withstand both heavy equipment as well as high foot traffic. That makes it a versatile option for any location.

On top of that, polished concrete offers a nice glossy finish that looks more modern. It doesn't have to look old and cracked, as you might expect. When treated with sealers or hardeners, your floor can resist both staining and excess moisture.

The downside of concrete lies in its hardness. It has a heavy impact on people who need to walk on it daily, and items dropped on concrete floors will break more easily. Concrete also doesn't retain heat well, which can create a colder environment.

Industrial Epoxy Flooring

Floor epoxy is another popular option for industrial settings due to its durability and resistance to wear and tear. Instead of replacing concrete floors, it is actually poured over them to create a smooth and seamless surface.

One of the benefits of clear epoxy flooring is that it allows the natural look of your floor to show through. However, you can also opt for some with tints or decorative flakes.

Any spills are easily wiped up, as they won't sink into the concrete floor underneath. It can even handle harsh chemicals and solvents without corroding or staining.

However, applying epoxy means preparing the surface well in advance. The concrete must be clean, dry, and properly profiled for good adhesion. Temperature and humidity can also affect the process.

Rubber Flooring

Rubber flooring is a great choice for industrial areas that need more shock-absorbancy. While concrete flooring can crack from heavy impacts, rubber helps to mitigate that impact. This subsequently means that anything dropped onto your rubber floor will also have a better chance of survival.

On top of that, this material is available in the form of floor tiles. If you've found that any of the rubber has become indented or marred, you can easily replace it with another tile. This also means that it's quicker to lay down than any other flooring or coating that requires time to set.

Rubber provides exceptional traction even in wet conditions, which makes it great for both indoor and outdoor settings. Your workers will also enjoy the softer underfoot if they have to spend many of their work hours standing.

Polyurethane Flooring

Polyurethane offers many of the same benefits as epoxy flooring. However, it has more flexibility, which makes it most resistant to impacts and thermal shocks. It's a good option if your industrial space is exposed to extreme temperatures.

While epoxy has resistance to a wide range of chemicals, polyurethane has even better resistance. It's also less likely to crack over time and has a faster curing time than epoxy. However, polyurethane also requires a concrete substrate that has been cleaned and prepped in advance.

The only downside is that polyurethane may be more expensive than epoxy, due to the cost of materials as well as its shorter lifespan.

Vinyl and Linoleum

Both vinyl and linoleum are much more commonly seen in commercial settings than in industrial ones. However, they can find some use in light industrial applications due to their ease of installation and cost-effectiveness.

Higher-grade vinyl can withstand heavy foot traffic and resist moisture. However, it's sensitive to certain chemicals and isn't the best for use with heavy machinery or equipment.

Linoleum flooring is eco-friendly, durable, and antibacterial. It's also biodegradable, which means your company can reduce its environmental impact. The limitations are that linoleum can be damaged by moisture and requires periodic sealing to maintain its appearance and durability.

While neither option is great for the main staging area where you perform all of your heavy work, they could serve as an affordable alternative for office areas, hallways, and storage areas.

Specialty Flooring

Your best option is to order specialty flooring specific to your space's requirements. Some of the most important qualities to look for in industrial flooring include anti-static properties, non-slip, durability, versatility, and a low maintenance cost.

For example, quartz aggregate resinous flooring combines high-performance resin with colored quartz aggregates. The end result is a durable and attractive flooring that is also low-maintenance. The quartz comes in a variety of colors and sizes, so you can customize it to your personal preference.

Alternatively, your work location may require an ESD floor to prevent unwanted static discharge. This is necessary in the electronics industry, where something as simple as a jolt of static discharge can completely destroy a circuit board.

If you wish to update your concrete floors, then you can't go wrong with staining and color-dying. Staining is the most popular way to enhance concrete's visual appearance and won't flake or peel away like with paint.

Find the Best Option for Your Industrial Space

Industrial flooring needs to meet certain standards or else you'll end up replacing it a few years down the line. Ideally, it will last you at least 10 years without too much damage in the meantime. You can leave it up to your flooring professional to find the best fit for your next project.

McCord Contractors, Inc. is your local industrial and commercial flooring and coating specialist. We offer our services in North Carolina, South Carolina, and Virginia. You can request a quote today to tell us more about your project and learn about our offerings.

Cole McCord leads McCord Contractors, bringing unparalleled expertise to the realm of industrial flooring and painting. Cole's dedication to quality and durability in flooring and painting solutions has solidified McCord Contractors' reputation as a trusted partner for businesses. His approach emphasizes the use of high-grade materials, meticulous craftsmanship, and innovative techniques, ensuring that every project meets strict standards of excellence. McCord Contractors is committed to enhancing industrial and commercial spaces, providing insights into the best practices for flooring and painting that stand the test of time.

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