TRADITIONAL FLOORING CHOICES

Laboratories and similar spaces have been designed and constructed for some time, so there is a good bit of experience on different flooring types that have been used in them. Following is a synopsis of three that have been used with mixed results.

• Finished concrete: Finished or sealed concrete is recognized as a hard and durable surface that is used in many commercial and industrial settings, so it seems logical that it would be considered for laboratories too. However, it falls short in a number of ways. First is that it is not necessarily chemical resistant. There are plenty of cases where the salts (chlorides) used for melting ice on concrete sidewalks or driveways have caused significant interactions (sometimes with reinforcing steel in the concrete) and deterioration of the concrete. The same can be true of many other chemicals used in laboratories. Secondly, concrete is prone to cracking, which causes porosity problems and hygienic issues. Third, it may get used and abused enough that its appearance over time will deteriorate, creating very poor long-term aesthetics. Fourth, people who need to stand or work on concrete for extended periods tend to experience discomfort in their feet and legs, both in short- and long-term working conditions. Clearly then, it can be difficult, if not impossible, to meet all of the physical and human considerations of laboratories by just using concrete without some other type of flooring on top of it.
• Vinyl flooring: This is a common choice for flooring in commercial and institutional buildings of all types, so it makes sense that it is considered for use in laboratory spaces in those buildings as well. Vinyl tile and sheet flooring typically offer an economical and versatile design option with many choices of color, textures, and features. Homogenous material is better suited to the heavy use in laboratories compared to heterogeneous options, but both typically include a top wearing layer of urethane. It is this layer that will bear the brunt of any spills, stains, damage, etc. It will also require the usual cleaning, waxing, stripping, and buffing processes associated with the maintenance of vinyl flooring. If the vinyl flooring is damaged, the damaged area will need to be removed and new flooring installed. The ease of doing that and the final appearance will vary depending on the specific product used.
• Resinous flooring: An often touted flooring solution for locations that need good hygiene and can hold up to harsh usage is resinous flooring. This is typically a pourable, continuous covering that essentially creates a monolithic floor surface. Some can have good resistance to chemicals and spills, although individual products do vary. It falls short in a number of other ways though. From a maintenance standpoint, it can chip, stain, or burn without a good way to either clean or repair it and restore it to its original appearance, thus making it look continuously “dirty.” Some maintenance teams find it is difficult to keep clean regardless since the surface is not like many other flooring surfaces. From a human standpoint, resinous flooring does not offer particularly appealing or compelling aesthetics. The colors are limited and visual relief is not easy to incorporate due to the monolithic nature of the flooring. Finally, even though it can be an improvement to standing on concrete, many people still do not find resinous flooring comfortable and would prefer something else.
• Epoxy flooring: An alternative to resinous flooring is found in two-part epoxy flooring systems. These provide similar traits as a resinous floor in that they provide a continuous covering over a substrate, such as concrete or other subfloor materials. However, they require a more difficult two-part installation that can take a bit more time in the field and be harder to control the quality of the installation. When finished, they often exhibit the same shortcomings as resinous flooring: poor aesthetics, not comfortable for users, more challenging to maintain, and poor ability to repair or replace areas that are chipped, stained, or burned.

RUBBER FLOORING AS A PREFERRED ALTERNATIVE

Architects, designers, and building owners who may have thought they were limited to only the three choices above for laboratory flooring are finding that there is a very compelling fourth alternative in rubber flooring. This material has a long history in life sciences buildings, including large-scale installations in both public and private institutions and corporations with many successful, durable, and attractive installations. As such, it is logical to look more closely at rubber flooring for laboratory settings, particularly since there are more options than ever before. Manufacturers offer a number of different rubber flooring products that have different characteristics suited to the various needs of buildings, particularly laboratory spaces.

Photo: DIA719

Rubber flooring can be used in laboratory spaces in a variety of types, colors, and performance levels to suit the particular project design.

Rubber flooring, like virtually all commercially available rubber products, is actually vulcanized rubber. Vulcanization is a chemical treating process (primarily using natural sulfur or other chemicals) in order to make rubber harder, stronger, more flexible, and more resistant to heat than in its untreated condition. Natural rubber that is not vulcanized is not suitable for products since it is very sticky to touch while the independent polymer chains inside the rubber naturally deform, allowing the rubber to melt if warmed and break apart if too cold. Introducing vulcanization to natural or synthetic rubber overcomes these issues by creating cross-link bonds at an atomic level, allowing a wide range of products to be made. The degree of vulcanization determines the ultimate characteristics as exhibited in everything from rubber elastic bands, automobile tires, and even bowling balls. Some rubber flooring products are also calendared, meaning they are treated with high heat and pressure to enhance their properties.

Manufacturing Process

Rubber flooring is commonly made from all natural materials harvested from rubber trees and then vulcanized to create the desired characteristics. During the manufacturing process, the rubber can be colored to be a strong, consistent color throughout, or it can have a pattern incorporated. The surface can be very smooth, slightly textured, or contain a pattern of raised round circles across the top side. The thickness of the rubber flooring can be controlled and produced to suit different needs for wear resistance and durability. Further product enhancements can be made to suit different applications, including those needed for laboratory settings.

From a design standpoint, rubber flooring can be used in labs similarly to other resilient flooring products. It is available in square tiles (nominally 24-inch or 48-inch squares) or continuous rolls of sheet flooring (nominally 48 inches wide by lengths of 40–50 feet). (Rectangular planks are also available, but not typically in products that are suitable for laboratory flooring.) Combined with an array of color options, this diverse set of offerings allow plenty of choices for creating patterns, inlays, design features, and other visually appealing elements. It is also possible to combine different products in one facility such that different rooms and places have similar flooring appearances while the different products meet the different needs of the spaces: laboratories, corridors, meeting spaces, classrooms, restrooms, etc. Manufacturers also offer a full range of accessories to go with the rubber products, including wall bases and adhesives, as well as complementary products like one-piece stair treads and risers.