The problem

Most ESD flooring systems are designed as thick epoxy coatings or modular mats, typically installed indoors during construction or major refurbishment. Over time, these systems can crack, delaminate, or tear—especially under heavy equipment, pallet movement, and forklift traffic.

Repairing damaged ESD floors often requires specialist contractors, extended downtime, or complete floor replacement.

The substrate

Existing concrete, epoxy-coated, or industrial flooring surfaces used in manufacturing, assembly, and logistics areas.

Why replacement was not viable

• High cost of removing and reinstalling ESD floor systems
• Production downtime during floor replacement
• Cracking and failure of thick epoxy systems under load
• Lack of outdoor and UV resistance in conventional ESD floors

The ProShieldESD solution

ProShieldESD was applied as a thin-film, two-part ESD coating directly onto existing factory floors. Unlike thick epoxy systems, the coating does not introduce internal stresses that lead to cracking.

Because the coating forms a thin, bonded layer, the load-bearing capacity of the floor remains unchanged. Heavy equipment movement, pallet traffic, and wheeled loads are handled by the substrate—not the coating.

Performance outcome

• Stable ESD performance across large floor areas
• No cracking or tearing under heavy loads
• Uniform charge dissipation across traffic zones
• Easy in-house touch-up of localised wear or scratches

Standards alignment

The converted factory floors support ESD control programs aligned with IEC 61340 and ANSI/ESD S20.20 requirements when integrated into a properly grounded flooring system.

Key benefits

• Converts existing floors into ESD-safe assets
• Avoids demolition, cracking, and long shutdowns
• Supports heavy equipment and vehicle movement
• Easy maintenance by in-house facility teams