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RESIN FLOORING

WE HAVE BEEN INSTALLING ALL TYPES OF RESIN FLOORING FOR OVER 30 YEARS IN SOME OF THE MOST DEMANDING INDUSTRIAL ENVIRONMENTS

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Select the correct type of flooring

Selecting the correct resin flooring solution for your businesses needs is essential to minimise future disruption to your operations, ensure good site safety, hygiene and maintenance.

Corroless Eastern are approved applicators for several manufacturers, offering the complete spectrum of flooring systems. From rapid cure slip-resistant resin flooring systems to steam cleanable polyurethane screeds we are able to pass on our knowledge and experience to you the client and provide a resin floor that is high quality and fit for purpose.

From aircraft hangar floors to taint sensitive food production areas, we have the solution.

  • Hangar Flooring

  • Food Factory Flooring

  • Workshop Flooring

  • Epoxy Flooring

  • Slip Resistant Flooring

  • Polyurethane Screeding

Minimal disruption

Completed to a tight timescale

Hard wearing and durable

Can be slip resistant

Aesthetically pleasing

Excellent value cost per square metre

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The history of Resin Flooring

Resin flooring has a history that spans several decades and has evolved in response to the need for durable, versatile, and aesthetically pleasing flooring solutions. Here’s a brief overview of the history of resin flooring:

  1. Early Developments (20th Century): The use of resins in flooring can be traced back to the mid-20th century. Early formulations often involved epoxy resins, which were known for their excellent adhesion properties and resistance to chemicals. These early resin floors were primarily used in industrial settings due to their durability and ease of maintenance.
  2. Industrial and Commercial Applications (1960s-1980s): In the 1960s and 1970s, epoxy resin flooring gained popularity in industrial and commercial applications. Industries such as manufacturing, automotive, and food processing started using resin floors for their resistance to chemicals, abrasion, and heavy loads. The seamless and smooth nature of resin flooring made it easy to clean and maintain.
  3. Advancements in Formulations (1980s-1990s): During the 1980s and 1990s, there were significant advancements in resin flooring formulations. Polyurethane resins were introduced, offering additional benefits such as enhanced flexibility and resistance to UV radiation. This expanded the range of applications beyond industrial settings to include commercial spaces like offices, retail, and healthcare facilities.
  4. Decorative and Aesthetic Options (2000s-Present): In the 21st century, resin flooring has become more popular in both commercial and residential spaces, partly due to advancements in aesthetics. Decorative options, including a wide range of colors, patterns, and finishes, have made resin flooring a versatile choice for architects and designers. This shift has led to the use of resin flooring in areas such as hotels, restaurants, galleries, and homes.
  5. Green and Sustainable Options: In recent years, there has been an increased focus on sustainability in construction materials. Manufacturers have responded by developing resin flooring options that are environmentally friendly, incorporating recycled materials and reducing volatile organic compound (VOC) emissions.
  6. Technological Innovations: Ongoing research and development continue to bring technological innovations to resin flooring. These innovations include self-leveling systems, faster curing times, and improved durability, further expanding the application possibilities.

Resin flooring is now recognized for its versatility, durability, and aesthetic appeal, making it a popular choice across various industries and spaces. The history of resin flooring reflects a continual evolution driven by advancements in materials, technology, and changing design preferences.

What are the benefits of resin flooring?

Resin flooring offers a variety of benefits, making it a popular choice in various industrial, commercial, and residential settings. Here are some key advantages of resin flooring:

  1. Durability: Resin flooring is known for its exceptional durability. It can withstand heavy foot traffic, impact, and abrasion, making it suitable for high-traffic areas such as industrial facilities, warehouses, and commercial spaces.
  2. Chemical Resistance: Resin floors, particularly those made with epoxy or polyurethane formulations, exhibit excellent resistance to a wide range of chemicals. This makes them suitable for industries where exposure to acids, alkalis, oils, and other corrosive substances is common.
  3. Seamless and Hygienic: Resin flooring is typically installed as a seamless surface, minimizing the presence of joints or seams where dirt and bacteria can accumulate. This seamless design contributes to easy cleaning and maintenance, making resin floors a hygienic choice for areas like kitchens, laboratories, and healthcare facilities.
  4. Customization and Aesthetics: Resin flooring offers a high level of customization in terms of color, texture, and finish. This allows architects and designers to create unique and aesthetically pleasing spaces. Decorative options include metallic finishes, terrazzo effects, and more.
  5. Quick Installation and Cure Times: Some resin flooring systems have fast curing times, allowing for quicker installation compared to traditional flooring materials. This can be advantageous in projects where minimizing downtime is crucial.
  6.  Slip Resistance: Many resin flooring formulations can be engineered to provide slip resistance, enhancing safety in areas where there may be a risk of slipping, such as commercial kitchens, wet areas, or entranceways.
  7. UV Stability: Certain resin flooring options, particularly those with polyurethane formulations, offer good resistance to UV radiation. This makes them suitable for both indoor and outdoor applications without concerns about color fading or degradation.
  8. Thermal Stability: Resin floors can withstand a wide range of temperatures, making them suitable for use in environments with varying climate conditions. They remain stable under temperature extremes without warping or cracking.
  9. Sound Reduction: Some resin flooring systems can contribute to sound reduction in interior spaces, providing a quieter and more comfortable environment.
  10. Sustainability: With advancements in formulations, there are now environmentally friendly and low-VOC (volatile organic compound) options available, contributing to sustainable building practices.

These benefits make resin flooring a versatile choice in various industries, including manufacturing, healthcare, retail, hospitality, and residential construction. However, the specific advantages may vary depending on the type of resin flooring system used and its intended application.

Types of Resin Flooring?

The FeRFA (Resin Flooring Association) is an organization in the UK that represents the resin flooring industry. FeRFA categorizes resin flooring systems into various types based on their characteristics and intended use. As of my last knowledge update in January 2022, here are the main types of resin flooring according to FeRFA:

Type 1 – High-Performance Industrial Screeds:
Description: High-strength, heavy-duty systems designed for industrial environments with heavy mechanical and chemical exposure.
Applications: Manufacturing plants, engineering facilities, chemical processing plants.

Type 2 – High-Performance Industrial Flooring:
Description: High-strength systems with good chemical resistance, suitable for demanding industrial environments.
Applications: Warehousing, chemical plants, manufacturing facilities.

Type 3 – Decorative Quartz Flooring:
Description: Decorative systems incorporating colored quartz aggregates for a visually appealing finish.
Applications: Showrooms, retail spaces, commercial environments.

Type 4 – Multi-Layer Flooring:
Description: Multi-layer systems offering a combination of properties, such as durability, chemical resistance, and aesthetics.
Applications: Commercial and industrial settings, laboratories, healthcare facilities.

Type 5 – Multi-Layer Flooring with Conductive Properties:
Description: Multi-layer systems designed to dissipate static electricity, providing a conductive flooring solution.
Applications: Electronics manufacturing, laboratories, clean rooms.

Type 6 – Flexible High Build Flooring:
Description: Flexible and resilient systems suitable for environments where some movement or flexibility is required.
Applications: Balconies, walkways, car park decks.

Type 7 – Heavy-Duty Flowable Flooring:
Description: Flow-applied, heavy-duty systems designed for areas with heavy traffic and impact.
Applications: Loading bays, car parks, industrial flooring.

Type 8 – Flexible Flowable Flooring:
Description: Flow-applied systems with flexibility for areas where movement or vibration is a consideration.
Applications: Mezzanine floors, ramps, areas with structural movement.

Type 9 – Resin Terrazzo Flooring:
Description: Decorative flooring systems incorporating resin and decorative aggregates for a terrazzo finish.
Applications: Commercial buildings, airports, high-end retail.

Type 10 – Moisture Tolerant Flooring:
Description: Flooring systems designed to tolerate residual moisture in the substrate during installation.
Applications: New construction projects, damp environments.

Type 11 – UV-Curing Flooring:
Description: Flooring systems that cure rapidly with ultraviolet (UV) light, allowing for quick installation.
Applications: Fast-track projects, areas with limited downtime.

Selecting the right resin floor for your application

Selecting the right resin floor involves considering various factors to ensure that the chosen flooring system meets the specific requirements of the environment and intended use. Here are key considerations when selecting a resin floor:

  1. Environmental Conditions:
    Chemical Exposure: Identify the types of chemicals or substances the floor will be exposed to. Choose a resin system with the appropriate chemical resistance for the specific environment.
    Temperature Variations: Consider the temperature conditions of the space. Some resin floors may be more suitable for extreme temperatures or temperature fluctuations.
  2. Usage and Traffic:
    Traffic Load: Evaluate the level of foot and vehicular traffic the floor will endure. Different resin systems have varying levels of durability, impact resistance, and load-bearing capabilities.
    Type of Traffic: Consider the nature of the traffic, such as heavy machinery, forklifts, or pedestrian traffic. Choose a resin floor that can withstand the specific demands.
  3.  Cleanliness and Hygiene:
    Seamlessness: Determine the importance of a seamless surface for cleanliness. Seamless resin floors are easier to clean and maintain, making them suitable for environments with strict hygiene requirements.
    Anti-Microbial Properties: In certain settings, such as healthcare or food processing, consider resin flooring systems with anti-microbial properties for added hygiene.
  4. Aesthetics and Design:
    Color and Finish: Consider the desired aesthetics of the space. Resin floors come in various colors, finishes, and decorative options. Choose a system that complements the overall design and ambiance of the area.
    Customization: Some resin flooring systems offer customization options, allowing for unique designs, patterns, or corporate branding.
  5. Durability and Longevity:
    Abrasion Resistance: Assess the need for abrasion resistance, especially in areas with heavy wear. High-traffic environments may require flooring with enhanced abrasion resistance.
    Impact Resistance: Consider the impact resistance of the resin floor, especially in areas where heavy objects or machinery may cause impacts.
  6. Installation Time and Downtime:
    Installation Speed: Evaluate the time available for installation. Some resin flooring systems, like UV-curing floors, offer rapid installation, minimizing downtime.
    Project Schedule: Consider the overall project schedule and select a flooring system that aligns with project timelines.
  7. Budget Constraints:
    Cost Considerations: Assess the budget for the flooring project. Different resin flooring systems come with varying costs. Consider the long-term benefits and maintenance costs along with the initial investment.
  8. Substrate Conditions:
    Substrate Compatibility: Ensure that the chosen resin flooring system is compatible with the substrate. Some systems may be suitable for concrete, while others may require specific preparation.
  9. Regulatory Compliance:
    Health and Safety Regulations: Ensure that the selected resin floor complies with health and safety regulations, including fire codes and other relevant standards.
  10. Maintenance Requirements:
    Ease of Maintenance: Consider the ease of maintenance. Some resin floors are designed for minimal maintenance, reducing long-term costs.

Consulting with flooring professionals such as Corroless Eastern, manufacturers, or industry experts can provide valuable insights and assistance in selecting the most appropriate resin flooring system for a specific application. Additionally, referring to industry standards and guidelines, such as those provided by organizations like FeRFA, can help ensure a well-informed decision.

Preparing for resin flooring

Proper preparation is crucial for the successful installation and performance of resin flooring. Here are the general steps involved in preparing for resin flooring:

  1. Surface Assessment: Evaluate the condition of the existing substrate (the surface on which the resin floor will be applied). Check for cracks, unevenness, contamination, or any other issues that may affect adhesion.
  2. Surface Cleaning: Thoroughly clean the substrate to remove any dirt, dust, grease, oil, or contaminants. Use appropriate cleaning agents and methods to ensure a clean and dry surface.
  3. Surface Repair: Repair any cracks, holes, or defects in the substrate. Fill gaps with suitable repair materials, and ensure that the surface is smooth and free of imperfections.
  4. Moisture Testing: Conduct moisture testing, especially for concrete substrates. Excessive moisture can negatively impact the adhesion and curing of resin flooring. Address any moisture issues before proceeding.
  5. Abrasive Blasting or Grinding: Depending on the type of substrate and the resin flooring system, abrasive blasting or grinding may be necessary to create a profile on the surface. This roughens the substrate, providing a better surface for adhesion.
  6. Removal of Existing Flooring: If there is existing flooring that needs to be removed, it should be taken up and the substrate prepared accordingly. Old adhesives, coatings, or residues should be completely removed.
  7. Priming: Apply a suitable primer to the prepared substrate. The primer enhances adhesion between the substrate and the resin flooring system. The choice of primer depends on the specific resin system being used.
  8. Coving Installation: In areas where a seamless transition between the floor and walls is required, consider the installation of coving. Coving helps create a continuous, easy-to-clean surface and prevents the accumulation of dirt in corners.
  9. Installation of Expansion Joints: Install expansion joints where needed to accommodate potential movement in the substrate. This is particularly important in large areas or where the substrate may experience thermal expansion or contraction.
  10. Application of a Damp-Proof Membrane: In situations where moisture ingress is a concern, apply a damp-proof membrane to prevent moisture from rising through the substrate.
  11. Verification of Readiness: Ensure that the substrate is thoroughly prepared and meets the requirements specified by the resin flooring manufacturer. Verify that the substrate is clean, dry, and free from contaminants.

It’s crucial to follow the specific guidelines provided by the resin flooring manufacturer for surface preparation, as different resin systems may have unique requirements. Additionally, compliance with industry standards and local regulations is essential.

How long will resin flooring last?

The lifespan of a resin floor can vary depending on several factors, including the type of resin flooring system, the environment in which it is installed, the level of traffic and use, and the quality of the installation. Here are some general considerations:

  1. Type of Resin System:
    Different resin systems have varying levels of durability. For example, heavy-duty industrial systems may have a longer lifespan compared to decorative or light-duty systems.
  2. Environmental Conditions:
    Exposure to harsh environmental conditions, chemicals, or extreme temperatures can impact the longevity of a resin floor. Resin floors designed for specific environmental challenges tend to have a longer lifespan in those conditions.
  3. Traffic and Use:
    The level and type of traffic the floor experiences influence its longevity. Heavy machinery, constant foot traffic, or the movement of heavy loads can contribute to wear and may reduce the lifespan.
  4. Installation Quality:
    The quality of the installation process is crucial. Proper surface preparation, application techniques, and curing procedures play a significant role in the durability and lifespan of the resin floor.
  5. Maintenance Practices:
    Regular and appropriate maintenance can extend the lifespan of a resin floor. Neglecting maintenance or using harsh cleaning agents may lead to premature wear and deterioration.
  6. Substrate Conditions:
    The condition of the substrate (the underlying surface on which the resin floor is applied) can impact the overall performance and longevity of the flooring system. Proper substrate preparation is essential.
  7. Resin Floor Thickness:
    Thicker resin flooring systems generally offer more durability and a longer lifespan. Industrial applications often require thicker coatings to withstand heavy loads and high impact.
  8. UV Exposure:
    Some resin systems are more resistant to UV radiation than others. If the floor is exposed to direct sunlight, UV-resistant formulations can help prevent color fading and deterioration.
  9. Quality of Materials:
    The quality of the resin materials used in the flooring system can affect its longevity. High-quality, durable resins are likely to result in a longer-lasting floor.
  10. Compliance with Standards:
    If the resin flooring system meets or exceeds industry standards and guidelines, it is likely to have a more predictable lifespan.

In general, well-maintained resin floors in low to moderate traffic environments can last 10 to 20 years or more. However, in heavy industrial settings with harsh conditions and high traffic, the lifespan may be shorter, and the floor may require more frequent maintenance or eventual refurbishment.

It’s essential to consult with flooring professionals, follow manufacturer recommendations for maintenance, and consider the specific requirements of the environment to maximize the lifespan of a resin floor. Regular inspections and proactive maintenance can help identify issues early and address them before they lead to more significant problems.

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