A brief introduction to the possibilities available for the seamless flooring sector: from the food and drinks sector to heavy industry or the chemical industry, as well as other solutions for the service sector and shopping centres, right up to floor coverings for more intimate and private areas inside the homes we live in. Mapei can play an important part in enabling projects of undeniable cultural and artistic quality and significance to become a reality, by proposing the most suitable solutions in terms of durability, functionality, finish and pattern in compliance with the technical and stylistic constraints specified by the client.

Mapei now has an increasingly large number of solutions available to cover all flooring needs efficiently and quickly: durable, resistant and versatile solutions for any space or room that form part of our normal daily routine.

ONE PRODUCT RANGE, MANY DIFFERENT RESULTS

In the seamless flooring sector in particular, the range of possibilities currently available meets the demands of every product category, thanks to the use of specific floor coverings suitable for use in numerous different types of surroundings: we just have to think of flooring in industrial environments, from the food and drinks sector to heavy industry or the chemical industry, as well as other solutions for the service sector and shopping centres, right up to floor coverings for more intimate and private areas inside the homes we live in.

THE ARTIST’S STYLE REALISED ON SITE

Solutions vary according to their area of use and are categorised by their performance characteristics - smooth or textured surfaces, by the finish or pattern which make them unique. Never identical or repeatable, each solution is a symbol of the compromise between the craftsmanship of the floor layer (these are floors applied skilfully by hand), and the specific requirements of each and every client when creating bespoke surfaces. This is the direction Mapei proposes for renovation work on historical buildings, examples of excellence in the world of art and culture where design is bound by the constraints of conservative restoration, yet there is the desire to break with conventions and to boldly highlight the differences in the effects of the various materials employed.

MATERIALS THAT GIVE THE FREEDOM  OF EXPRESSION

And herein lies the choice, right from the very first approach to a design - to diversify the basic themes inherent to the use of the materials, not only according to their performance characteristics and the patterns or finishes governed by the colours and textures to be used, but above all according to themes more in context with the design itself: monochromatic, stripped-down resin systems or cementitious solutions characterised by soft textures and non-uniform pigmentations?

In certain cases, it is possible to maintain the old flooring to exalt the expressive differences between the old structure and the new, re-coated seamless surfaces (one of the advantages of applying resin systems is certainly the fact that the layers applied are only a few millimetres thick), allowing designers to highlight, quite clearly and decisively, the stylistic and materic difference between an existing historic structure and the smooth, simple, clean, sober flooring, albeit absolutely functional in view of its final destination as a space to be used by the community.

Completely different, on the other hand, are those designs which aim to achieve more stylistic continuity within the structure and where the search for just the right material leads, for example, to the use of a self-levelling cementitious formulate. In such cases, the use of cementitious mortar strengthens the historical-artistic features of the original structure (such as in the case of the museum presented on the following pages), turning it into a more orderly, silent and intimate environment where visitors perceive a strong sense of reassurance during their visit.

No longer are there clear, separate margins when proposing and choosing a flooring system: areas with the same final use can have their own identity, thanks to the choice of different materials which, for their very nature, are able to make the context perfectly congruent with the initial design choices.

Once again, Mapei can play an important part in enabling projects of undeniable cultural and artistic quality and significance to become a reality, by proposing the most suitable solutions in terms of durability, functionality, finish and pattern in compliance with the technical and stylistic constraints specified by the client.

Resin flooring systems only became an established solution in the building industry over the last few decades, but they represented a turning point regarding the level of protection they provide and the improvement in performance of surfaces completed with them.

Nowadays there are various types of systems available in a range of different materials and thicknesses, with varying levels of mechanical strength or resistance to chemicals, with non-slip and anti-static properties and finishes that are easy to disinfect, as well as many other characteristics in order to target the specific requirements of certain sectors of industry.

Why do we tend to say “resin system” rather that “resin coating”?
The word “system” is far more appropriate, in that it expresses the concept that the solution proposed and applied is not just a simple layer of product (coating), but rather a combination of several layers that are applied in a specific way to form a system in which the layers work together to achieve the final performance properties of the system.

Can I apply a resin system anywhere I like?
No. A system that has been designed and applied correctly will meet the performance properties specified for the flooring for a long time, but it will still need to be maintained and looked after. There are obviously systems that are easier to maintain than others and which are more resistant to routine cleaning and sanitising operations, and they are usually so thick that they can be used for a very long time before having to intervene to refurbish or repair them. It depends on the type of system.

So how many types of system are available?
Systems can be made from various materials, in different thicknesses and with various types of layers. The most commonly used products are made from epoxy or polyurethane resin, but there are also other mixtures of these types of resins available with cementitious binders to make products with their own particular performance properties. Numerous systems can be created, each with its own particular set of performance properties, depending on the type of material used, how much material is applied, the number of layers applied to form the system and the application technique used. For instance, Italian standard UNI 10966 devotes a whole section to the design and completion of this kind of floors in interiors and exteriors.

There are mixtures of two types of binder available that seem to be poles apart; cement and synthetic resin. Can you give us an example?
The most obvious example is the range of polyurethane/cementitious products, which are a well-calibrated blend of polyurethane resins, cementitious binders and various types of aggregates. The fascinating thing about these products is that the two binders, one mineral and the other organic, react and then interact with each other to form a product that, one set, has exceptional performance properties and mechanical characteristics. And as far as the simplicity and the time required is concerned, they are the perfect example of what I was talking about earlier regarding the maintenance requirements of the system.

The products from the MAPEFLOOR CPU line by Mapei, where CPU stands for Cement-Poly-Urethane, have been on the market for around a decade and have met with wide approval from numerous satisfied clients. They are used to form systems in thicknesses varying from 3 to 9 mm. The technology behind these products dates back to the late 1970’s, but it was only in the last twenty years that it finally caught on in the industrial sector where requirements such as high strength, resistance to chemicals and heat, impermeability, quick application and ease of maintenance are particularly important. They started to be used mainly in the food and beverage sector and in the chemical and pharmaceutical industries, but also in other sectors.

Polyurethane systems can have a smooth or non-slip finish, depending on the shape and size of the aggregates that are sometimes added, to give flooring non-slip properties and ensure safe working conditions.

Why does the thickness vary from 3 to 9 mm?
Thickness is very important with regards to resistance to impact loads and, above all, thermal inertia. Not only are MAPEFLOOR CPU systems resistant to high temperatures when in service, and much more resistant than traditional systems, they are also resistant to sudden changes in temperature, or what is known as thermal sock. The thicker the system, the higher the maximum temperature the system can withstand. And they can even resist temperatures of up to 120°C!

Can I buy this type of material and apply it myself?
We strongly recommend against doing that! Resin-based systems, and especially polyurethane/cement-based systems, require experience, skill and the right tools to apply them that only specialised teams possess.