Any busy warehouse operator will know the constant movement of pallet jacks is the heartbeat of daily operations—and that the flooring beneath quite literally lays the foundations for efficiency and safety. This is why selecting the right flooring material for your mezzanine system is vital, especially for areas subjected to heavy rolling loads such as pallet jacks.
While plywood has long been a staple in flooring solutions, there is a rising star that offers an even better performance: particleboard. In this blog, we will unpack the advantages of particleboard over plywood, focusing on durability, cost-effectiveness and maintenance, to help you make an informed decision for your flooring needs.
Strength in simplicity: the basics of plywood and particleboard
Plywood is manufactured by peeling thin layers from wood logs, which are then glued together under heat and pressure to form cohesive sheets. These sheets are cross-laminated for added strength. Plywood is known for its strength due to the cross-grain pattern of its layers, making it a durable choice for various applications.
On the other hand, particleboard is composed of wood chips or particles bonded together with adhesive under heat and pressure. The result is a smooth, uniform surface that is less prone to warping compared to plywood. While plywood's strength is often highlighted, particleboard has distinct advantages, particularly in environments where rolling loads are part of your day-to-day operations.
Durability under rolling loads: particleboard vs. plywood
One of the critical factors in choosing flooring for an industrial mezzanine is durability under rolling loads. Plywood, despite its strength, is prone to delamination when subjected to the stresses of pallet jacks. Sharp turns can cause the top veneer layer to peel away, leading to delamination. This problem is exacerbated by the fact that the top layer of plywood is relatively soft, making it susceptible to track indentations from pallet jack wheels. Over time, these indentations increase the risk of delamination, compromising the integrity of the flooring.
In contrast, particleboard, especially the 38mm Unilin offered by Unistor, lends superior resistance to these issues. The uniform composition of particleboard ensures that the entire board can withstand the stresses imposed by rolling loads without delaminating. The smoother surface of particleboard also reduces the risk of track indentations, providing a more hardy and long-lasting flooring solution.
Considering cost-effective flooring materials
Cost is always a significant consideration when choosing flooring materials. Plywood, while strong, is more costly than particleboard. This cost difference can be particularly impactful in large-scale installations where extensive areas need to be covered. Additionally, the potential for delamination and the associated maintenance costs can further increase the overall expense of using plywood.
Particleboard, on the other hand, is a more cost-effective solution. Its lower initial cost, combined with reduced maintenance expenses due to its durability, makes it an attractive option for many businesses. By choosing particleboard, companies can achieve substantial savings without compromising on quality or performance over time.
Maintenance and longevity
Maintaining flooring in industrial settings can be challenging, particularly when dealing with materials like plywood that are prone to wear and damage. Plywood floors can develop splinters and cracks, creating trip hazards and making it difficult to transport wheeled loads. Additionally, plywood is susceptible to water damage, which can lead to staining and further deterioration.
In contrast to this, particleboard offers a more resilient solution. Its smooth, uniform surface is easy to clean and maintain, and it does not suffer from the same issues with splinters or cracks as plywood. Within this vein, our 38mm Unilin particleboard is specifically engineered to resist moisture, reducing the risk of water damage and extending the life of the flooring.
The issue of warranty and replacement
Another critical factor to consider is the issue of warranty and replacement. Clients who have experienced delamination with plywood flooring often find it challenging to claim warranty coverage, as proving that pallet jacks were not overloaded can be difficult. This often results in the need for costly floor replacements, which can be a significant burden for businesses.
By choosing particleboard, you can mitigate these risks. The robust nature of particleboard reduces the likelihood of damage, and our 38mm Unilin panelling is backed by a 5-year guarantee on all workmanship.
Environmental considerations
In the environmentally conscious market of today, the sustainability of materials is an important consideration. Particleboard is made from wood particles that would otherwise be waste, making it a more sustainable choice compared to plywood, which requires the use of whole logs. Additionally, our particleboard is manufactured using environmentally friendly adhesives, further reducing its environmental impact.
The clear choice for rolling loads
All in all, when it comes to selecting flooring for areas subjected to rolling loads, particleboard—specifically Unistor’s 38mm Unilin panelling—offers clear advantages over plywood. Its superior resistance to delamination, cost-effectiveness, ease of maintenance, and environmental benefits make it the ideal choice for businesses looking to install durable and reliable flooring.
Partner with Unistor for tailored mezzanine flooring solutions
With over thirty years of experience as Australia’s leading manufacturer and supplier of mezzanine flooring solutions, our team at Unistor know the ins and outs of what makes a mezzanine project successful. We offer end-to-end project services from consultation, design, engineering to installation, ensuring you deal directly with the manufacturer—a point of difference that can save you thousands in the long run.
Selecting the appropriate flooring material is not just about aesthetics; it is about efficiency, return on investment and compliance. Investing time and resources in ensuring the right foundation for your mezzanine system can save costs, enhance safety and improve operational efficiency in the long run. Make sure you have all the necessary information and professional guidance to make it a successful, safe and cost-effective addition. With Unistor by your side, you are already a step ahead.
With the right choice of flooring, you can ensure a safe, efficient and cost-effective working environment for years to come. Contact us today and experience the Unistor difference.
