What Different Types of Commercial Rubber Flooring Rolls

The primary types are defined by material composition—typically recycled Styrene-Butadiene Rubber (SBR) or virgin EPDM rubber—and the manufacturing process, which is either vulcanized or non-vulcanized. These factors, along with specific thickness and density metrics, dictate the flooring’s real-world performance and lifespan.

On my production floor, these are not abstract terms; they are critical process variables that define the end product’s capabilities. Recycled SBR, derived primarily from commercial truck tires, is our high-durability, high-value option. Its inherent toughness makes it the default choice for high-impact zones like weightlifting areas. Virgin rubber, such as Ethylene Propylene Diene Monomer (EPDM), is synthesized from raw polymers. This allows for precise control over its chemical structure, resulting in superior color uniformity, UV stability, and a non-porous surface essential for sterile applications. The manufacturing method is equally critical. Vulcanization subjects the rubber to heat and pressure, creating permanent molecular cross-links. This transforms it into a single, thermoset material. Non-vulcanized rolls are granules bound with a polyurethane adhesive. Both are durable, but their performance under stress is fundamentally different.

Understanding these technical distinctions is crucial for proper specification. A wrong choice can lead to premature failure and operational disruption.

Why Does Material Composition Matter for Performance?

Material composition directly dictates the flooring’s physical properties. Recycled SBR offers superior tear strength and value, making it ideal for mechanical loads. Virgin EPDM provides chemical and UV resistance with a hygienic, non-porous surface, essential for healthcare and laboratory environments.

Let’s be specific. The SBR we use comes from end-of-life truck tires, which are engineered for extreme durability. This gives the resulting flooring incredible resilience against dropped weights and heavy equipment. It is the most practical choice for a gym’s bottom line and performance needs. However, it is microscopically porous and will absorb fluids if they are left to sit. EPDM, on the other hand, is built from the molecule up. We can guarantee a closed-cell structure. This is not just a feature; it’s a requirement for environments that undergo regular chemical sterilization. An architect specifying flooring for a hospital operating room must choose a non-porous material like virgin EPDM or vulcanized rubber to meet health and safety codes. The choice is driven by the application’s non-negotiable requirements.

The raw material determines potential. The manufacturing process determines how much of that potential is realized.

Is Vulcanized Rubber Always the Better Choice for Durability?

Yes, for chemical resistance and structural integrity, vulcanized rubber is objectively superior. The process creates a thermoset material that is non-porous and monolithic. It will not delaminate, and it offers the highest resistance to harsh chemicals, solvents, and extreme wear.

The distinction is simple from a material science perspective. A non-vulcanized roll consists of SBR granules bonded together with a high-strength polyurethane binder. While very strong, the binder itself can be a point of failure if exposed to incompatible chemicals. A harsh solvent could attack the binder, compromising the floor’s integrity. Vulcanization avoids this entirely. We use heat and sulfur to create covalent sulfur-sulfur bonds between the rubber polymer chains. The process turns the entire roll into one single, massive molecule. It’s a thermoset material, meaning its structure is permanently set. You cannot melt it down or break the bonds without destroying the material itself. This monolithic structure is why vulcanized rubber is specified for automotive garages, industrial facilities, and labs where chemical spills are a risk. The surface is completely sealed and exceptionally dense, offering the ultimate protection.

With the material science decided, the final step is specifying the physical dimensions based on the expected mechanical loads.

How Do I Choose the Right Thickness and Density for My Application?

Base thickness on the maximum expected point load and impact. For free-weight areas, specify a minimum of 8mm to prevent subfloor damage. For density, target 900 kg/m³ or higher to resist indentation from heavy equipment. These are not suggestions; they are engineering minimums.

Thickness is for impact protection. Density is for durability against static loads. An 8mm thick roll can absorb the energy from a dropped 100lb dumbbell, preventing that force from cracking the concrete subfloor beneath. Specifying a 4mm or 6mm floor in this scenario is negligence; it will lead to costly structural repairs. Density, measured in kilograms per cubic meter (kg/m³), indicates how much material is compressed into the volume. A low-density floor will show permanent indentations from the feet of heavy squat racks. A high-density floor (900 kg/m³ or more) will support the load and rebound. Another key metric is Shore A hardness, which measures resistance to indentation. A rating between 60-70 provides an optimal balance of firmness for stability and cushion for comfort and safety. Choosing the wrong specs doesn’t just mean the flooring wears out faster; it means you risk damaging the building’s foundation and creating a hazardous environment.

Proper specification is the most critical part of the procurement process. It ensures safety, performance, and long-term value.

Conclusion

Properly specifying a commercial rubber floor means matching the material, manufacturing process, thickness, and density to the application’s exact mechanical and chemical demands.

My team provides the technical expertise to ensure your flooring specification is correct from an engineering standpoint. We help you avoid costly mistakes. Contact us for a technical consultation, a quote based on your performance requirements, or to request material samples for testing.