Table of Contents:
Table of Contents:
05-28-2025
A durable, high-performing floor is a critical component of any facility —but small mistakes during installation can lead to years of headaches and unexpected costs. By proactively avoiding common errors, facility managers, construction professionals, and plant engineers can ensure longevity and performance from their flooring investments. Below, we outline key insights and solutions to achieve flawless flooring installations.
Common Mistakes to Avoid
Mistake #1: Installing Flooring After Equipment Setup
Would you install flooring at home without clearing out heavy furniture? The same principle applies to industrial and commercial facilities.
Installing flooring before equipment placement ensures that your installation team has proper access to prepare and achieve proper bond of the flooring to the substrate. Poor access leads to wasted time, hindered preparation, and subpar installation. Once the floor is installed, it can be protected during equipment setup. This approach eliminates downtime further down the line and provides a stronger, more durable floor that will withstand the rigors of your operations.
Key takeaway: Prioritize floors before equipment installation to maximize long-term performance.
Install flooring before equipment for proper prep, better bonding, and long-term durability.
Mistake #2: A “Run to Failure” Maintenance Approach
Just like vehicles need oil changes and regular maintenance to avoid breakdowns, floors require care to remain effective. Relying on a reactive “fix it when it’s broken” mindset can result in escalating damages and costly shutdowns. Instead, adopt a proactive approach through periodic inspections with your flooring provider.
Addressing smaller issues early avoids the need for larger-scale repairs or replacements. Partnering with a flooring company that values longevity over frequent replacements ensures your investment remains cost-effective for years to come.
Key takeaway: Implement a maintenance plan with semi-annual inspections to extend the life of your floors.
Regular inspections catch small issues early, preventing costly repairs and downtime.
Mistake #3: Unrealistic Scheduling and Empty Promises
Promises of overnight installation and zero disruptions sound appealing but are often impractical. Rushed installations result in poor-quality work, delays, and potentially costly operational setbacks. A contractor who is honest about timelines and limitations is far more reliable than one who over-promises.
Request a detailed, hour-by-hour written scope of work from your contractor. This ensures realistic expectations and allows your team to plan operations accordingly.
Key takeaway: Choose flooring contractors who provide clear, realistic timelines backed by a comprehensive installation plan.
Trust contractors who offer realistic timelines and a clear scope of work.
Mistake #4: Layering Good Flooring Over Bad Foundations
Covering an old, deteriorating floor with a new layer might seem convenient, but this “lipstick on a pig” method rarely works. Layering new flooring over compromised substrates is a costly shortcut that increases the likelihood of future problems like cracking and peeling. Substrate preparation is a crucial first step in the flooring installation process and it can significantly impact the appearance and longevity of the final flooring material.[1]
Before committing to a new installation, invest in core sampling or adhesion testing to assess the condition of existing layers. These tests offer valuable insights to help avoid compound issues and ensure your investment is spent wisely.
Key takeaway: Conduct thorough floor testing before installation to avoid throwing good money after bad foundations.
Core sampling and adhesion testing reveal what’s beneath to prevent costly future failures.
Mistake #5: Poor Drain Integration
Drains are a common failure point in flooring systems, especially in industries like food and beverage manufacturing. Materials such as stainless steel, resinous flooring, and concrete expand and contract differently. This leads to stress points and cracking, especially at square drain edges. Poorly designed drainage systems are not just a nuisance but a significant risk to floor integrity.
Ensure collaboration between your flooring contractor and plumber to align on the best type of drains for your facility. Choose drains specifically designed to accommodate the unique conditions of your space, keeping stress points minimized.
Key takeaway: Collaborate early with contractors and plumbers to design effective, durable drainage solutions.
Seamless floors need properly integrated drains — poor transitions can lead to cracks, leaks, and costly repairs.
Why Getting It Right Matters
Mistakes during flooring installations can disrupt operations, reduce the lifespan of your floors, and increase future repair costs. By avoiding these pitfalls, you ensure that your floors are not just functional, but an asset to the reliability and safety of your facilities.
At Stonhard, we’ve spent decades helping facilities avoid these mistakes. Our seamless flooring systems combine durability, hygiene, and aesthetic appeal with solutions customized to your unique operational demands.
Stonhard delivers seamless, customized solutions built for durability, hygiene, and long-term performance.
Partner with the Experts
With more than a hundred years of experience and countless successful projects, we know what it takes to deliver lasting results. If you're seeking expert advice, detailed planning assistance, or quality flooring that lasts, Stonhard is here to help.
Reach out to your local Stonhard expert today to discuss your next project and ensure your flooring installation is defined by trust, quality, and reliability.
About Stonhard
Stonhard is the unprecedented world leader in manufacturing and installing high-performance polymer floor, wall and lining systems. Stonhard maintains 300 territory managers and 200 application teams worldwide who will work with you on design specification, project management, final walk-through and service after the sale. Stonhard’s single-source warranty covers both products and installation.
Contact us to learn more about our precision installation methods and specialized products.
About The Author
David Senn
David Senn is Stonhard's Global Accounts Manager. He specializes in team leadership, creative problem solving, global agreements, and developing scalable platforms to deliver client-focused solutions. David holds a Masters in Business Administration from Kent State University.
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