Raised access floors have become a staple in modern building design, especially in office environments, data centers, and other facilities where cabling, electrical wiring, and air distribution need to be managed efficiently. This article delves into the manufacturing process of raised access floors and highlights the top manufacturers in the industry globally.
The Manufacturing Process of Raised Floor Systems
1. Design and Material Selection
The manufacturing process begins with design and material selection. Raised access floors are typically made from steel, aluminum, or wood core panels. The choice of material depends on the intended use, load requirements, and environmental factors.
Steel floor access panels are popular for their durability and load-bearing capacity. They are usually covered with a high-pressure laminate, carpet, or vinyl to provide a finished look and additional durability. Aluminum panels are lightweight and resistant to corrosion, making them suitable for clean rooms and environments with high humidity. Wood core panels, often made from high-density particleboard, offer a balance between strength and cost-effectiveness.
2. Computer Floor Tile Manufacturing
Once the materials are selected, the raised floor tiles are manufactured through a series of steps:
- Cutting and Shaping: Raw materials are cut and shaped into the desired panel dimensions using precision machinery. The standard size for raised floor panels in the US is imperial 24″ x 24″ and Europe, Asia, Middle East, and Canada are typically metric 600mm x 600mm.
- Surface Treatment: The panels undergo surface treatment processes such as galvanization for steel panels or anodization for aluminum panels to enhance corrosion resistance.
- Core Filling (if applicable): For wood core panels, the core is filled with high-density particleboard, which is then encased in a steel or aluminum shell for added strength.
3. Raised Floor Systems Finishing and Coating
After the panels are manufactured, they are coated with a finish to improve durability and aesthetics. Common finishes include high-pressure laminates, vinyl, and carpet. The finishing process involves:
- Applying Adhesives: A layer of adhesive is applied to the panel surface.
- Laminating: The chosen finish material is laminated onto the panel using heat and pressure to ensure a strong bond.
- Trimming and Edge Sealing: Excess material is trimmed, and the edges are sealed to prevent moisture infiltration and damage.
4. Under-structure Manufacturing
The under-structure, which supports the raised floor panels, consists of pedestals and stringers. The manufacturing process for these components involves:
- Pedestal Manufacturing: Pedestals are typically made from steel or aluminum and consist of a base plate, a threaded rod, and a head assembly. The components are welded or assembled using precision machinery.
- Stringer Production: Stringers are horizontal beams that connect the pedestals and provide additional support. They are usually made from steel and are cut and shaped using precision cutting tools.
5. Assembly and Quality Control
The final step in the manufacturing process of raised access floors is the assembly and quality control of the raised access floor system:
- Assembly: The panels, pedestals, and stringers are assembled to form a complete system. This step ensures that all components fit together perfectly and function as intended.
- Quality Control: The assembled raised floor system undergoes rigorous quality control tests to ensure it meets industry standards. These tests include load-bearing capacity, fire resistance, and acoustic performance.
Top Manufacturers of Raised Flooring
Several companies have established themselves as leaders in the raised access floor industry due to their commitment to quality, innovation, and customer satisfaction. Here are some of the top manufacturers globally:
1. Kingspan Access Floors
Kingspan is a leading manufacturer of raised access floors, known for their innovative designs and high-quality products. Kingspan owns and operates both Tate and ASM. two of the US’s largest US manufactures. Their offerings include a range of panel types, understructure systems, and finishes to suit various applications. Kingspan’s commitment to sustainability and energy efficiency has made them a preferred choice in the industry.
2. Hayworth
Haworth is renowned for its versatile and robust raised access floor solutions. They offer a variety of panel options, including steel, aluminum, and wood core panels, along with customizable finishes. Haworth’s products are designed to meet the demanding requirements of modern office environments and data centers.
3. ZT Floor
ZT Floor was founded in 1988, with an area of 80,000 square meters and 260 employees. ZTFLOOR leverages its 30+ years of experience in the industry to provide support to customers by its high efficiency, energy conservation, intelligence and green spaces products. Contact Pro Access Floors for the complete ZT Raised Access Floor product line.
4. Polygroup
Polygroup is a well-established manufacturer of raised access floors, known for their innovative designs and high-performance products. Their offerings include a variety of panel options, understructure systems, and finishes to suit different applications. Polygroup’s commitment to sustainability and energy efficiency has made them a preferred choice for many projects worldwide.
5. Triumph Modular
Triumph Modular offers a range of raised access floor solutions designed to meet the specific needs of various industries. Their products are known for their robust construction, ease of installation, and adaptability to different environments. Triumph Modular’s focus on quality and innovation has earned them a solid reputation in the market.
Conclusion
Raised access floors play a crucial role in modern building design, offering flexibility, improved cable management, and enhanced airflow management. The manufacturing process involves careful material selection, precision engineering, and rigorous quality control to ensure the final product meets industry standards. Leading manufacturers like Kingspan, Haworth, ZT Floor, Lindner Group, Polygroup, Fieldmans Access Floors, and Triumph Modular have set the benchmark for quality and innovation in the raised access floor industry.
Choosing the right raised access floor system and manufacturer is essential for achieving optimal performance and longevity. By understanding the manufacturing process and the top players in the market, you can make informed decisions that align with your project’s specific needs and requirements. Get started now with DIY Raised Access Floor Kits from Pro Access Floors.