Heavily filled polymer floors are the “heavy artillery” of industrial flooring systems. They are designed for facilities where other flooring types (even standard self-levelling systems) fail within months due to extreme mechanical, thermal, or chemical stress.
The key feature of this system is the high content of graded quartz sand (up to 70–85% of the total mass), bound with epoxy or polyurethane resin. The thickness of such a floor ranges from 4 to 10 mm, making its strength comparable to natural granite.
Where are heavily filled floors used?
These systems are essential in high-wear environments:
- Heavy industry and metallurgy (workshops with large machines and risk of falling heavy tools and parts)
- Heavy-duty vehicle traffic zones (depots, military hangars, unloading areas with intense truck traffic)
- Chemical, oil refining, and electroplating plants (constant exposure to acids, alkalis, and solvents)
- Food industry plants and slaughterhouses (high-pressure steam cleaning, shock freezing zones)
- Ramps, elevated platforms, and outdoor areas (freeze, UV exposure, and abrasive wheel wear)
Why are heavily filled floors considered “armoured”?
Essentially, the quartz sand takes over all mechanical loads and impacts, while the polymer resin acts as an ultra-strong and flexible binder that locks the grains into a single monolithic structure.
- High-impact strength. The thick flooring layer absorbs impacts and withstands objects weighing hundreds of kilograms without chipping or cracking.
- Exceptional wear resistance. The linear expansion of the system is very close to concrete. The floor does not delaminate under load and lasts over 30 years.
- Thermal resistance. The coating withstands thermal shock (e.g., boiling water or steam cleaning up to +120°C) as well as extreme frost conditions.
- Concrete repair capability. Due to its thickness, the system can level and “heal” deep potholes, cracks, and uneven old concrete surfaces.
- Adjustable anti-slip effect. Depending on the sand fraction, the surface texture can be adjusted from slightly rough to very coarse, which is critical for wet production areas.
Types of heavily filled systems
- Industrial (solid colour). Uses clean quartz sand with a top polymer sealing layer in any RAL colour.
- Decorative (Color Quartz). A blend of coloured quartz aggregates with a transparent topcoat. It creates a natural stone-like appearance with industrial-grade strength.
Protect your business from constant floor repairs! Contact our engineer for consultation and an accurate cost estimate of a heavily filled flooring system for your facility.