There are various options on the market for robotic flooring solutions, in this blog we compare two of the most common ones available.
The first being the ‘click tile’ solution. The rubber and PVC tiles have been a firm favourite for some time on mezzanines because they are quick to install and are relatively inexpensive.
However, when used with robotics they can create challenges. If tiles are not properly adhered to the mezzanine deck, they can become loose. As robots move across and past each other, they create a bow-wave effect, causing the tiles to ‘pop’ due to opposing pressure that causes a micro lift in the tile. Moreover, if the tiles were originally glued down, replacing them may damage the underlying boards.
Rubber flooring is highly sensitive to temperature changes, making it essential to consider expansion and contraction during installation. As temperatures rise, rubber naturally expands, while colder conditions cause it to contract. Without an appropriate expansion gap, this movement can lead to significant buckling, warping, or gaps.
Another factor to consider is when the floor is cleaned, the tight fit between the tiles acts like a capillary and will draw the moisture down underneath the tiles. Even if the deck below is waterproof, there is nowhere for that moisture to go, so it can cause smell issues and cause the timber to swell up. Normally, its local to the joint of the tile, so you end up with the four sides curling up which creates anomalies that the robot can’t travel over, but over time they grow and grow until you have a very uneven deck and a much bigger issue. The decks themselves will need replacing or drying out, which is very costly. Likewise, in the event of a fire and the sprinkler system being triggered the boards will be prone to water damage on a large scale.
Another option we see on the market, is a high strength composite board with a thin resin system over the top. UK mezzanines rarely accommodate this flooring system due to their construction using purlins – horizontal beams spaced with gaps that can cause installation challenges with this system. In contrast, US mezzanines often use “crinkly tin” – corrugated metal decking that creates a continuous, stable base, making installation easier for this type of system. As a result, flooring systems designed for the US may require modifications for UK mezzanines. However, the standard UK mezzanine board used with Robot Floor is readily available and widely used.
The resin coating on these boards is relatively thin (0.8mm to 1.2mm), limiting its lifespan in high-wear robot settings. One of the major factors with resin floors is the thicker they are the longer they last, and contrary to what you might think, this is not because there is more of it to wear through, it’s because the top layer is significantly stronger than what is beneath it. Even if you have a high-strength board underneath, its compressive strength might be just ten newtons. With a 1mm resin system on top providing eighty newtons of strength, the surface won’t withstand eighty newtons. This is because the load disperses through the resin system, and by the time it reaches the board, it exceeds the board’s tolerance. So, in lighter applications this solution works well, but in heavier applications there can be issues. What’s more, this type of solution requires a heavier mezzanine deck, so more steel is used, and the construction is more expensive.
And again, in the event of a sprinkler system being activated with this solution, there is no protection below. The boards are installed with small gaps between which causes damage if water does get through. These small gaps can also create noise, producing a noticeable ‘rattle’ as robots pass over them. With hundreds of robots operating simultaneously, the noise can be disruptive, especially in structures without noise insulation.
Ultimately, choosing the right flooring for robotics isn’t just about the surface material, it’s about ensuring long term reliability, minimising maintenance costs, and efficiency. Understanding these trade offs will help businesses invest in flooring that supports their long term business objectives, reduces downtime, and sustains performance in demanding environments.
