Preparing Facilities for AGV Integration

Table of Contents:

05-05-2026

Automation is rapidly transforming manufacturing, warehousing, distribution environments, and more. As automated guided vehicles (AGVs) and autonomous mobile robots (AMRs) become more common, facility managers are discovering that successful deployment depends on more than software and sensors. The floor itself plays a critical role in performance and safety.

When planning for the installation of AGV-ready floors, the question is not just whether a surface can handle traffic, but whether it is engineered for robotic traffic. Below are considerations for retrofits and new construction projects preparing for AMR integration.

Automation is transforming warehouse corridors. Built for AGVs and AMRs, seamless floors are engineered for precision, durability, and safety.

Why Flooring Matters for AGV and AMR Integration

AGVs and AMRs rely on precision. They follow programmed routes, use sensors to detect obstacles, and depend on consistent floor conditions to operate efficiently. Surface irregularities, static buildup, excessive joints, and surface wear can shorten equipment lifespan.

A scientific review of sensing technologies for indoor autonomous mobile robots highlights how modern AMR navigation systems integrate multiple sensor modalities to perceive and respond to environmental conditions and maintain accurate localization and path tracking. These systems are highly sensitive to irregularities in the traversable surface, which can introduce noise into sensor data, compromise odometry accuracy, and reduce positional precision, reinforcing the importance of smooth, uniform flooring for reliable robotic performance.[1]

Unlike forklifts or manual carts, robotic systems operate continuously. This means wheel-path wear is concentrated and repetitive. Without robotic flooring solutions specifically designed for this kind of traffic, facilities may experience premature deterioration or static-related interference.

Precision Grinding and Surface Flatness

For AGV-ready floors, flatness and smoothness are foundational. Even minor deviations can affect navigation accuracy and wheel performance.

In retrofit scenarios, existing concrete may show signs of joint deterioration or uneven wear. Floor surveys are required to determine floor flatness and levelness and will determine the amount of patching and/or precision grinding required for proper surface preparation to restore a profile and ensure adhesion for new systems.

In new builds, specifying floor flatness and levelness requirements early helps avoid costly corrections later. Consistency is critical. Robotic systems perform best on surfaces with predictable texture.

Seamless Surfaces for Predictable Performance

Seamless floors eliminate the interruptions caused by grout lines and tile transitions. For AGV and AMR integration, this reduces vibration, prevents debris accumulation, and limits the potential for tracking errors.

High-performance, seamless resinous floors provide AGVs and AMRs with:

A durable surface that resists abrasion, impact, chemical exposure, and concentrated traffic

A continuous surface that supports smooth wheel movement

Easy cleaning reduced maintenance needs

Minimization of areas where dirt and dust can accumulate

Seamless floors keep warehouse corridors running smoothly, eliminating joints that cause vibration, debris buildup, and tracking issues.

Anti-Static and ESD Considerations

Static electricity can interfere with sensitive electronics and onboard sensors. In environments where AGVs or AMRs operate near electronic assembly lines, data centers, or sensitive packaging operations, anti-static or electrostatic dissipative (ESD) flooring may be required.

Anti-static coatings help control charge buildup and provide predictable conductivity across the floor surface. For facilities planning AMR integration, evaluating electrostatic control early in the design phase ensures compatibility with both robotic systems and production equipment.

Stonshield ESD aisles help control static while withstanding the production demands in this aerospace facility.

Materials Engineered for Robotic Traffic

Engineered resinous systems can be formulated for enhanced abrasion resistance and compressive strength. They also provide better long-term performance compared to untreated concrete, which can crack or deteriorate under constant robotic traffic.

When evaluating AGV-ready floors, facility managers should consider:

Compressive and tensile strength

Abrasion resistance

Resistance to wheel-path wear

Compatibility with automation systems

Long-term maintenance requirements

Selecting the right material reduces downtime and extends both flooring and equipment life cycles.

Engineered resinous floors are built to handle constant robotic traffic, offering superior strength, abrasion resistance, and long-term performance.

Retrofitting Existing Facilities

For facilities upgrading to automation, retrofitting presents unique challenges. Existing slabs may have surface damage, joint issues, or inconsistent flatness. A thorough evaluation of the substrate is essential before deploying AGVs or AMRs.

Key retrofit steps include:

Assessing concrete condition and moisture levels

Repairing cracks and deteriorated joints

Precision grinding for flatness and profile

Installing seamless, high-performance resinous systems

Considering anti-static coatings where needed

Retrofitting offers an opportunity to address long-standing floor issues while preparing the space for robotic traffic. Proper preparation ensures that automation investments are not compromised by subpar flooring.

Planning Flooring in New Builds

In new construction, coordination between facility managers, design teams, and flooring specialists is critical. Planning AMR integration at the design stage allows teams to specify floor flatness tolerances and incorporate electrostatic control where required.

New builds also provide the opportunity to engineer traffic patterns and wheel paths into the flooring specification, ensuring durability in high-use areas. Designed with automation in mind, facilities can avoid future disruptions and costly upgrades.

Building the Foundation for Automation

Automation investments are significant, and their success depends on every component working together. Floors are not simply a passive surface but rather a structural and operational foundation for AGV and AMR performance.

Whether retrofitting an existing space or planning a new automated facility, evaluating AGV-ready floors, seamless resinous systems, and anti-static solutions is essential. Robotic flooring solutions engineered for durability, precision, and long-term performance help ensure that AMR integration delivers on its promise of efficiency 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.

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About The Author

Ed De Asis

Ed De Asis is a Product Engineer for Stonhard and has been with the organization since 2023. He current focus is on ESD product development and he is CXLT certified. De Asis graduated from Rowan University with a B.S in Mechanical Engineering.