Forklifts are essential in industrial settings, but they can be harsh on floors, causing damage that leads to high maintenance costs, operational downtimes, and safety risks. Odus Flooring provides a lasting solution with its advanced concrete regeneration technology, designed to protect against forklift wear and tear, improve safety, and reduce maintenance costs.

In the article below we have listed 8 common problems due to forklift operations, their scientific reasons and how Odus treatment helps to solve them.

Problem # 1: Damage of Concrete Floor

Even M30 grade concrete floors suffer damage due to forklift movements. The forks end up scratching the top layer of the floor. Thus leading to scratches, hairline cracks, top layer getting removed and even potholes.

The primary reason for such damage is that hardness of Forklift (Mohs = 3.5) is more than the Hardness of Floor (Mohs = 1.5 to 2.5 for concrete)

Therefore, even after repairing again and again, there are frequent occurrences of floor damage.

How Odus helps to prevent concrete floor damage:

Odus Flooring strengthens concrete floors from within, repairing existing damage and ensuring long-term durability by protecting against future wear.

Scientific Explanation:

Odus treatment increases the density of the topmost layer of concrete, significantly improving its hardness. After treatment, the hardness of concrete floors on the Mohs scale (Mohs scale ranges from 1- softest to 10- Hardest) increases from less than 3 to between 4.5 and 6.5. Forklifts which have a Mohs scale of 3.5, are therefore less likely to cause abrasion on the treated floors.

Material	Hardness (Mohs Scale)
Concrete Floor (Before Treatment)	<3
Concrete Floor (After Treatment with Odus)	4.5 - 6.5
Forklift	3.5

Note: Odus does not increase the compressive strength of floors or protect against damage from point loads or movements beneath the surface.

Problem # 2: Frequent repairs and re-coating of Epoxy and PU

Epoxy and PU coatings are commonly used to create dust-free environment in factories. However, they are easily damaged by forklifts. Typically under forklift operations, the life of Epoxy Floors is 9-12 months; and the life of PU floors is 1.5-3 years. After this they require re-coating.

Material	Mohs Hardness	Lifespan under forklift operations
Epoxy Floor	<2	9 - 12 Months
PU Floor	1.5 - 2.5	1.5 - 3 years
Forklift	3.5
Odus Treated floor	4.5 - 6.5	> 5 years

How Odus Helps Prevent Frequent Epoxy and PU Repairs

Odus treatment transforms regular concrete into dust-free concrete, eliminating the need for floor coatings like Epoxy and PU altogether.

Due to their low Mohs scale (<2), Epoxy and PU coatings wear out under forklift operations. Odus offers a more robust solution by increasing the floor’s hardness and abrasion resistance.

The Mohs scale of Odus-treated floors ranges from 5 to 7, which is higher than the hardness of forklifts (3.5). This makes the floor resistant to forklift damage and extends its lifespan.

Problem # 3: High Maintenance Costs

Frequent floor repairs and forklift maintenance can lead to significant operational downtime and increased costs. This creates a cycle: floors become uneven due to damage from forklifts, and forklifts require more maintenance from operating on uneven surfaces.

How Odus helps to reduce floor and forklift maintenance cost:

By making floors more resilient to scratches and other damage from forklifts, Odus addresses common challenges such as floor undulations, forklift safety, and frequent repairs. The concrete regeneration technology strengthens the floor and ensures long-term durability, eliminating the need for repeated repairs or reapplication of coatings.

Additionally, by optimizing the smoothness of the floor, it addresses challenges such as tire wear, tire marks, and improves battery life.

Odus Flooring dramatically reduces overall maintenance costs. In just 1.5 years, Odus has saved its clients over Rs 25 crore by reducing floor maintenance expenses.

Problem # 4: Safety Hazards Like Forklift Toppling

Running forklifts on uneven surfaces poses significant safety hazards, including the risk of toppling, especially during sharp turns or sudden braking.

How Odus helps to ensure safety of forklift operators:

By leveling the surface and eliminating floor undulations, Odus Flooring reduces the risk of forklift toppling, making operations smoother and safer.

Problem # 5: Slippery Floors

Floors that are too smooth can become slippery, especially during braking or turning, leading to safety risks for both forklifts and pedestrians.

How Odus helps to get slip free floors:

Odus Flooring creates a non-slippery surface by maintaining an optimal coefficient of friction. The friction coefficient of Odus floors is 0.32 when dry and 0.29 when wet, both of which exceed the minimum requirement of 0.25 for a non-slip surface. This ensures that forklifts can turn, brake, and operate safely without slipping.

Problem # 6: Tire Marks on Floor and Tire Wear

Forklift tires wear out quickly on undulated or highly frictional surfaces like concrete floors. As they wear, the rubber becomes worn out and gets stuck to the floor, leaving tire marks.

On epoxy floors, frictional heat melts both the epoxy coating and the tire rubber, causing them to stick together, which results in further tire wear and leaves marks on the floor.

How Odus helps to reduce tire wear and prevent tire marks on floor:

Odus Flooring helps create a level floor and optimize the coefficient of friction, thereby preventing excessive wear on forklift tires. By maintaining a balanced level of friction, tires do not overheat, reducing both tire wear and the formation of tire marks.

The coefficient of friction for an Odus floor is 0.29 when wet and 0.32 when dry. This optimal frictional coefficient balances smooth operation with a non-slip surface.

Unlike epoxy coatings, Odus-treated floors do not melt under heat because they have no coatings at all. This ensures that rubber from the tires does not stick to the floor, further reducing maintenance requirements.

Problem # 7: Reduced Battery Life in Forklifts

The battery life of forklifts running on smooth floors is 1.3 X more than the life of forklift batteries running on an uneven floor.

How Odus helps to improve forklift battery life:

Odus Flooring creates a smooth and leveled surface that allows forklifts to operate efficiently. The smoother the floor, the less energy is required for movement, which in turn extends the battery life of forklifts.

Floor Problem 8: Lubricant absorption and Difficult Cleaning

Bare concrete floors are porous, allowing fluids like oil and water to penetrate and damage the floor over time.

In the case of epoxy and PU-coated floors, the presence of lubricants weakens the bond between the base floor and the coating, leading to immediate peeling of the epoxy and PU layers.

How Odus makes floor cleaning easier:

Odus treatment decreases the porosity of the top layer of concrete, slowing the penetration of fluids. The smooth surface created by Odus makes it easy to clean and wipe away any fluid spills. Since Odus-treated floors are unaffected by oil, moisture, or lubricants, they offer superior long-term protection compared to traditional coatings.

Conclusion: Long-Term Cost Savings and Durability

By addressing forklift-related issues and enhancing the strength and durability of factory floors, Odus Flooring offers a long-term solution for industrial settings. It significantly reduces maintenance costs, increases the lifespan of floors, and improves the efficiency and safety of forklift operations.

In just 1.5 years, Odus has saved its clients more than ₹25 crore in maintenance costs. It’s a one-time investment that eliminates the need for repetitive treatments, making it the ideal choice for any facility looking to create a forklift-proof floor.

Summary Table

Problems	Issue Description	How Odus Helps	Scientific Explanation
Forklift Damage to Floors	Floors often get damaged, with coatings peeling off, cracks, and potholes.	Odus strengthens floors from within, fixing damage and protecting them from future wear. No need for coatings like Epoxy or PU.	It makes the top layer of concrete denser, increasing its hardness (from <3 to 5-7 on the Mohs scale).
Frequent Epoxy and PU Repairs	Forklift tires wear out quickly, leaving marks on the floor due to friction and heat.	Odus reduces both tire wear and marks by optimizing friction and eliminating coatings that cause sticking.	No coating means no frictional heat, so nothing sticks to the tires.
High Maintenance Costs	Uneven floors drain forklift battery life faster.	By smoothing and leveling the floor, Odus helps forklifts run more efficiently, extending battery life.	Same as Forklift 1, Odus smooths the floor, reducing operational strain.
Safety Hazards with Forklifts	Forklifts are more likely to topple on uneven surfaces, posing safety risks.	Odus creates smooth, level floors that make forklift operations safer and prevent toppling.	Again, similar to Forklift 1—smoother floors mean fewer hazards.
Slippery Floors During Forklift Operations	Forklifts can slip during turns or braking on overly smooth floors.	Odus floors provide just the right grip with a coefficient of friction of 0.32 (dry) and 0.29 (wet), preventing slips.	The friction level is perfect for preventing slips, according to American standards (min 0.25).
Tire Marks and Wear on Floors	Damage to floors and tires leads to high maintenance costs.	By solving problems like floor damage and tire wear, Odus cuts down on maintenance costs significantly.	Odus-treated floors are tougher and last longer, reducing repair needs.
Reduced Forklift Battery Life	Forklift operations scratch and wear down floors.	Odus increases the floor's resistance to wear and tear, protecting it from scratches.	With a hardness rating of 5-7 on the Mohs scale, the floors can handle heavy use.
Fluid Penetration and Cleaning Difficulty	Factory floors typically use Epoxy or PU coatings that get damaged by forklifts, needing constant reapplication.	Odus makes floors dust-free and more durable than coatings like Epoxy or PU, eliminating the need for frequent re-coating.	Odus floors are harder (Mohs scale 5-7) than the forklifts themselves (Mohs 3.5), meaning they don’t get damaged easily.
Fluid Absorption and Difficult Cleaning	Bare concrete floors absorb oils and fluids, making cleaning difficult.	Odus reduces the floor’s porosity, making it easier to clean and resistant to fluid absorption.	The densified surface slows down fluid penetration and makes clean-up simple.
High Long-Term Maintenance Costs	High long-term costs due to constant floor damage and repairs.	Odus offers a long-term solution that avoids the need for constant patchwork, saving time and money.	Since Odus works from within and doesn't rely on surface coatings, floors stay durable without needing frequent fixes.