Taking The Mystery Out Of Selecting ESD Flooring

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• Will a repaired area match the original area surrounding it?

• How much time is required to both perform repairs and then wait for the repaired area to dry or cure before normal plant operations can resume?

• Would a combination of materials address the application better than trying to service the entire facility with one solution?

Again, regardless of the material you choose, at some point in the future you’ll be faced with damage, or even just wear and tear, that requires the repair or replacement of parts of your floor. Careful planning today will eliminate problems tomorrow.

Choosing A Supplier
The task of finding a good installer might actually be more critical than identifying which floor will be used. Although some installers can provide advice about materials and performance, their real value lies in their years of experience and familiarity with floor preparation, removal of old floors, concrete protection and installation coordination. Even the best and most durable material, improperly installed, is subject to problems like delamination, oozing adhesive and moisture vapor problems, which can create a never-ending nightmare for their owner. In extreme situations, problems from a poor installation can halt operations in an entire facility. Imagine, for example, the cost of shutting down a clean-room in order to remove and replace tiles or the impact of moving a surface-mount line because a coating is blistering and peeling from hydrostatic pressure.

A top-notch installer anticipates and prevents the auxiliary costs, which can actually exceed the initial investment, associated with repairing a bad installation. Many flooring manufacturers can provide a list of recommended installer/suppliers. These suppliers are usually regional companies with professional mechanics who install a host of other flooring materials, such as ceramic tile, VCT, hardwood and different types of carpeting. Often, these full-service companies are already doing work in the same buildings requiring ESD flooring. With adequate technical support from a reputable manufacturer, these local installers can provide great value and critical ongoing service.

In the quest for competitive edge, some ESD flooring manufacturers have started providing turnkey installation services. Factory installation teams employed by the flooring manufacturer are usually more familiar with the idiosyncrasies of ESD flooring than their local counterparts. The one downside to a factory installation is the handling of inevitable repairs and expansion. It is cost-prohibitive to send factory installers to a job site thousands of miles away to perform cleanup and repair. It is equally unrealistic to assume that a local professional will eagerly come in and repair a job done by someone else when they feel they should have gotten the original job in the first place.

Anyone who has ever observed a flooring demolition in an operational factory would describe the scene as an ugly one. Dust, chemicals and odors from demolition adversely affect the air quality in the plant. The grinders and blastrac equipment are noisy. The entire process, which is extremely disruptive, adversely affects the appearance of the plant during repairs. Depending upon the type of floor, some demolitions expose old sub-floors containing small percentages of asbestos, which must be removed in a contained environment by properly protected professionals. Because of space constraints, reinstallation of the floor may be much more difficult and time consuming than the original job. In some cases, it is even possible that the floor cannot be replaced without irreparably affecting a mission-critical manufacturing schedule. The best way to avoid these problems is to address them upfront. It’s always best, before starting any project of this magnitude, to do all of your homework.

Final Thoughts
Today, companies have a wider than ever variety of flooring materials from which to choose. The plethora of ESD flooring options includes waxes and finishes, vinyl and rubber tile, epoxies and urethane coatings, and broadloom carpet and carpet tiles. Since almost any traditional flooring material can be manufactured with some level of static protection, buyers rarely need to compromise on ergonomics, durability or appearance. And, no matter what the application, there’s always more than one option.

When a contract manufacturer in Massachusetts was contemplating an ESD floor for their new addition, they had several needs to address. The new floor plan located a major office area in an open mezzanine directly above the manufacturing floor. The floor had to have sound absorption properties, so their office workers wouldn’t be distracted by the manufacturing noise. But they also needed tough, durable aisle-ways that could withstand punishment from forklifts and pallet jacks.

At first, their needs seemed mutually exclusive. With input from their architect and a suggestion from an ESD flooring specialist, they decided to explore the possibility of using two different materials. The building owner visited the EMC factory in Franklin, Massachusetts and saw the perfect solution to their problem: a combination of ESD carpet tiles transitioning to a shiny textured conductive quartz coating.

The key to success is forming an unbiased partnership that incorporates strong ESD fundamentals with a background in sub-floor and concrete protection, maintenance and flooring installation. Whether the application calls for the hardness and abrasionresistance of epoxy-type coatings or the comfort and sound-deadening advantages of carpet, the right supplier and solution are out there.

© 2002 Conformity

David H. Long is the principle of Staticworx®, based in Newton, MA. He can be reached by phone at (617) 923-2000 or by e-mail at dave@Staticworx®.com. Staticworx® can be visited on the web at http://www.Staticworx®.com/.