Why Industrial Floors Change So Quickly

Slip resistance in industrial environments behaves very differently from commercial and residential flooring. Warehouses, factories, logistics centres, distribution hubs, loading docks, workshops, cold rooms, food production areas, and processing lines all experience wear conditions that alter the surface microtexture at a faster rate than almost any other sector.

Dust, grit, pallet movements, forklift wheels, grease vapour, overspray, cleaning agents, coatings, and temperature cycles all contribute to drift in slip resistance. Unlike new surfaces tested in controlled laboratory conditions under AS 4586:2013, industrial floors must be assessed in the field under AS 4663:2013, which measures how the surface performs after installation and after exposure to real contaminants.

Industrial environments are where the gap between “as manufactured” and “as used” becomes most visible. Understanding how slip resistance changes in these spaces is essential for WHS compliance, operational safety, and risk management.

Why Slip Resistance Degrades in Industrial Settings

Industrial flooring materials—including epoxy coatings, polyurethane resin floors, vinyl composites, textured concrete, and safety tiles—are engineered for durability. But even these enhanced products degrade.

Six key factors contribute to slip resistance drift:

1. Dust, Powder and Particulate Build-Up

Industrial sites or Distribution Centres often produce airborne particulate from:

• cardboard fibres
• packaging dust
• cement or plaster
• milled materials
• food powders
• timber residues
• grain, flour, and starch
• metalworking dust

These particles settle into surface pores and valleys, smoothing the microtexture that the pendulum slider relies on for traction.

Even “clean” surfaces may appear polished due to packed dust layers, reducing BPN values significantly.

2. Abrasion from Foot Traffic and Machinery

Industrial floors face far greater mechanical wear than commercial spaces. Examples include:

• forklift tyres
• pallet jacks
• wheeled bins
• conveyor drips
• trolleys
• equipment movement
• motor vehicles

This abrasion gradually flattens the microtexture peaks. A surface that initially tested P4 or P5 can drift to P2 within months depending on load, frequency, and weight transfer.

3. Coating Drift and Wear Patterns

Coatings applied to concrete or tiles—such as epoxy, polyurethane, urethane-cement hybrids, anti-slip treatments, and sealers—change over time due to:

• curing
• mechanical abrasion
• polishing from foot traffic
• chemical attack
• temperature cycling
• UV exposure on external loading docks

In many cases, coatings cure harder and smoother than the underlying material, reducing slip resistance as they age.

Additionally, coatings applied unevenly can create inconsistent friction zones, which become pronounced under AS 4663:2013  testing.

4. Oils, Grease and Mist

Industrial environments often have airborne contaminants:

• hydraulic aerosol
• lubricant sprays
• machining coolant
• animal fats (in food manufacturing)
• fryer oil vapour
• chemical residues

These land on the floor as microfilms that significantly reduce traction, even when invisible. Cleaning may not remove them if detergents are not matched to the contaminant type.

5. Moisture and Temperature Variation

Cold rooms, freezers, and refrigerated dock areas repeatedly cycle between condensation and dryness. Water condenses on surfaces and mixes with fine contaminants, creating intermittent slip risks.

Textured resin surfaces also stiffen in cold temperatures, changing their friction performance compared to ambient conditions.

6. Cleaning Practices

Incorrect cleaning is one of the largest contributors to slip reduction. Factors include:

• detergent residue left on the floor
• incompatible chemicals
• polishing effect from scrubbers
• insufficient dwell time
• mop-and-bucket systems redistributing contaminants
• over-sealing or re-sealing without stripping

These issues often cause a measurable drop in Pendulum BPN values.

Why AS 4663:2013 Testing is Essential for Industrial Settings

AS 4663:2013 is the national standard for slip resistance testing of existing pedestrian surfaces. Unlike AS 4586 laboratory tests, which measure performance of new materials under controlled conditions, AS 4663:2013 measures how surfaces behave in situ, with all real-world variables present.

This includes:

• wear
• contamination
• slope
• cleaning practices
• coatings
• environmental factors

Industrial sites need AS 4663:2013 testing because lab results do NOT represent operational performance.

Testing Methods Used Under AS 4663:2013

Industrial onsite testing uses the same instruments as AS 4586:2013 but the results are interpreted differently.

Wet Pendulum Test (Primary Method)

The Pendulum style Portable Skid Resistance Tester is used onsite to measure wet slip resistance at specific locations.

During an industrial assessment, technicians typically:

• test multiple zones
• areas identified by client based upon operational hazards
• select areas showing wear patterns
• avoid aggregates, joints and defects unless required
• test both “cleaned” and “as found” surfaces if relevant
• assess slope with digital inclinometers
• measure temperature and conditions
• document environmental factors

Results are compared to the P-classification table in AS 4586:2013 for reference, though AS 4663:2013 focuses on actual BPN values and performance in use.

Dry Floor Friction Test (Supplementary Method)

Using a Floor Friction device, the technician measures the coefficient of friction (COF) on dry areas.

Industrial dry zones can be deceptively risky because:

• smooth resin floors polish quickly
• cleaning residue builds up
• dust accumulation acts like a thin lubricating layer
• you cannot see dust & contaminants

The dry test identifies friction changes not detected by eye.

Common Industrial Findings from AS 4663:2013 Testing

1. Original P4 surfaces testing at P2

This is extremely common in warehouses six to twelve months after installation.

2. Uneven slip performance across different zones

High-traffic paths, forklift lanes, and “turning” points often test substantially lower than peripheral areas.

3. Coating failure due to incompatible cleaning

Strong alkaline or solvent cleaning can break down resin surfaces, altering slip resistance.

4. Contaminant drift

Dust and overspray often create measurable BPN changes in areas not directly exposed to contamination sources.

5. “Shiny floor effect”

Visually glossy patches indicate mechanical wear and correspond with lower friction values.

6. Incorrect or degraded anti-slip additives

Over time, aggregates within coatings become buried, polished, or worn away.

Compliance Considerations

Industrial facilities typically fall under higher-risk WHS categories. Slip resistance testing demonstrates:

• due diligence
• risk identification
• safety management
• data-driven maintenance planning
• defensible evidence for insurers and regulators

Testing also supports investigations after slip incidents by establishing measurable benchmarks.

How Often Industrial Floors Should Be Tested

Recommended frequencies vary based on risk:

• High-risk manufacturing: every 6 months
• Cold storage, food handling: every 6 months
• Logistics and warehousing: every 6 months
• Coating changes or resurfacing: immediately and 3 months post-application
• Post-incident: as soon as possible
• Heavy forklift traffic areas: every 6–12 months

Regular testing creates a friction “performance profile” that helps facilities anticipate maintenance needs.

Improving Slip Resistance in Industrial Settings

After testing, common corrective actions include:

• deep cleaning to remove microfilm
• switching detergent chemistry
• resurfacing with anti-slip coatings
• adding aggregates to existing coatings
• mechanical re-texturing
• improving drainage
• isolating contaminant drift sources
• increasing cleaning frequency & outcomes in high-wear zones

Each recommendation should align with the measured BPN results and operational requirements.

Why Industrial Slip Testing Protects Business Operations

Industrial slip testing is not just a compliance exercise. It protects:

• worker safety
• production continuity
• insurance integrity
• public liability exposure
• maintenance budgets
• surface lifespan

Drift in slip resistance is predictable, measurable, and manageable—as long as the facility collects accurate data and responds accordingly.