RESIN FLOORING
ONCE the decision to install a resin floor has been made, the real work begins. Because understanding the right specification for your facility is far from straightforward but with the right approach it can be easy to achieve a long-lasting finish that avoids the need for expensive downtime later on.
Resin floors are seamless, polymer-based surfaces which are applied in liquid form directly to a prepared surface and cure chemically to form a durable, abrasion-resistant finish. Yet there’s no one-size-fits-all system. The chemistry and thickness are just some of the factors to consider, along with variables such as resistance to chemicals, thermal shock, types and volume of traffic, as well as slip resistance.
Customers often ask for a resin floor without fully considering what they’ll need from it. Luckily, it’s fairly simple to ensure the final product meets their needs, owing to 10 simple steps.
Understand resin floors
Resin floors are formulated using synthetic resin binders, usually made of Epoxy, polyurethane, polyaspartic, PU cement and methyl methacrylate. They’re applied to a prepared substrate, where a chemical reaction ‘cures’ the liquid to provide the final finish. Different resin types provide different combinations of application, characteristics, and performance. The right system for your facility, then, will depend on its unique use case.
The Resin Flooring Association (FeRFA) categorises systems according to thickness and formulation. Type 1, for example, is classed as floor seal, has a thickness of up to 150μm, and is suitable for light duty. At the other end of the scale, Type 8, or heavy-duty resin flooring systems, contain specialist aggregates and are impervious throughout their more than 6mm of thickness, meaning it’s suitable for very heavy duty.
This is why careful consideration is crucial when specifying a resin floor.
Avoid false economy
On a 500sq m area, a Type 3 system, or high-build epoxy coating, may cost about £20 per sq m, or £10,000, to install. If used in a high-traffic area, however, it may need to be replaced in about two years.
A Type 8, or heavy-duty resin flooring system, costs more, at about £60 per sq m or £30,000 for a 500sq m area but will last for a decade or more.
In this context, selecting a thin system for a heavy-duty environment becomes a false economy. Even before considering inflation or repair costs, the lifecycle cost of repeated replacement can exceed the cost of a single heavy-duty installation.
Importantly, the real cost is not the floor itself, but in the shutdown.
Every time a production facility closes for floor replacement, the operational loss can far exceed the cost of a new floor. Lost manufacturing time, labour disruption, and product delays often dwarf the material price difference.
Consider how the area will be used
Remember that usage determines system type, thickness, and durability requirements. Is the space, for example, a dry production room, a warehouse, a logistics hub, or a wet washdown area?
Whereas a pharmaceutical packaging suite may experience light foot traffic, a finished goods warehouse may operate forklifts seven days a week.
It’s not just what traffic occurs but how frequently. Constant forklift loading demands a heavier-duty system than occasional pallet movement. Thicker systems, such as FeRFA Types 4 to 8, are designed for medium- to very heavy-duty environments, whereas thinner coatings, or Types 1 to 3, suit lighter use.
Consider chemical exposure levels
Next, consider the chemicals, including those used for cleaning and sterilising, that the floor may come into contact with, as well as the extent, frequency, and temperature of any spillage.
Food production may involve aggressive cleaning chemicals, and pharmaceutical or chemical plants may use acids or solvents. FeRFA types 1 to 3 aren’t generally recommended here as the thin layer is susceptible to impact damage, and more likely to suffer thermal shock or struggle to cope with regular washdowns.
Of course, not all chemicals will lead to structural failure, and some will discolour though not damage a floor. The key to maximising the system’s life expectancy is selecting the correct resin chemistry for your facility.
Consider extreme temperatures
Manufacturing facilities often need to contend with extreme temperature variations. Steam cleaning will expose flooring to temperatures of up to 120deg C, for instance, while blast freezers may operate as low as -40deg C. Considerations include the type, nature, and duration of exposure.
Some resin systems typically perform well up to around 120deg C, depending on the chemistry and thickness. Certain chemistries soften at temperatures above 60deg C, which, when trafficked can cause them to be damaged easily. The right chemistry will ensure your floor performs in various temperature variations.
Consider hygiene versus slip risk
Where floors are regularly wet, systems must include slip resistance, which is achieved by adding aggregates to create texture in the surface finish.
In the UK, the main method of measuring slip resistance is the pendulum test, in which a rubber slider is swung across a floor surface to simulate heel strike, with the distance it travels translating to a numerical pendulum test value (PTV).
The Health and Safety Executive (HSE) mandates a minimum PTV of 36 for commonly wet areas, from food manufacturing washdown areas which are cleaned with chlorinated foams, to manufacturing environments, where oils and grease are commonplace.
However, increased texture can affect cleanability, so the right balance must be struck between safety and hygiene.
Consider the type and condition of the substrate
Resin flooring follows the profile of the substrate, whether that’s concrete or screed. If the substrate is pitted or damaged, a screed system may be needed to bring the surface back to level to provide a consistent, durable and suitable surface
Is there a dampproof membrane?
Older buildings may lack a functioning dampproof membrane (DPM). Without proper moisture control, certain epoxy systems can blister or fail.
As such, moisture-tolerant systems or a surface-applied DPM may be necessary. Knowing this early on helps avoid expensive remediation later down the line.
Will production continue running during Installation?
In food and pharmaceutical facilities especially, installation must often occur during limited shutdown windows.
Odour control, avoiding taint, dust management and fast curing times can be critical factors. In some cases, a more robust system installed during a planned shutdown is preferable to repeated short closures for repairs.
Does the facility have special requirements?
Certain environments require additional properties of their resin flooring. Electronics manufacturers or facilities where powders or solvents may be used, for example, may need electrostatic dissipative (ESD) flooring to mitigate the risks.
Food production areas may need hygienic, impervious systems, and pharmaceutical operations may require systems that comply with good manufacturing practice (GMP) regulations.
All this should be built into the original specification to ensure the final product meets the facility’s individual needs. And, of course, if a building’s use changes, the floor specification should be reviewed accordingly.
The bigger picture
When correctly specified, resin flooring systems can deliver seamless, hygienic, high-performance surfaces for well over a decade.
The key is early consultation and honest discussions around operational demands, environmental conditions, maintenance expectations, and the true lifecycle cost. Because when viewed through the lens of total cost of ownership, investing in the right system from the outset is almost always the most economical decision.
Reference: FeRFA. (2024). Guide to the specification and application of synthetic resin flooring.
Available at: https://ferfa.org.uk/guide-to-the-specification-and-application-of-synthetic-resin-flooring/
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