What Is ESD and Why It Matters

Electrostatic discharge (ESD) occurs when a static charge builds up and suddenly releases. While a small spark might seem harmless, in precision environments it can:

  • Damage sensitive electronics and robotics

  • Corrupt data or disrupt automation systems

  • Cause explosions in flammable areas

  • Endanger operators handling delicate equipment

In facilities where automation drives productivity, a single uncontrolled discharge can cost thousands in downtime and damaged goods.

How ESD Flooring Works

ESD flooring prevents static buildup by providing a controlled path for electricity to safely dissipate to ground.

Unlike standard epoxy or polished concrete, ESD systems incorporate conductive elements such as carbon fibers or metallic particles that spread static charges evenly across the surface.

There are three primary types of ESD floors:

  1. Conductive (ECF): Highly conductive; designed for electronics and data centers.

  2. Dissipative (ESD): Slower transfer rate; safer for people interacting with machinery.

  3. Anti-static: Reduces charge buildup but does not conduct current to ground.

Where Static Is Most Dangerous

ESD control is critical in facilities where static can interfere with or damage processes. Examples include:

  • Electronics Manufacturing: Prevents PCB and microchip damage.

  • Robotics and Automation: Protects control systems from interference.

  • Pharmaceutical and Biotech: Maintains sterile, electrically stable environments.

  • Data Centers: Reduces static interference with servers and drives.

  • Explosive/Flammable Environments: Prevents ignition from static sparks.

Epoxy vs. Urethane for ESD Applications

Both epoxy and urethane flooring systems can be engineered for static control, but their performance depends on use case.

ESD Flooring Explained: Key Specs, Tests, and Use Cases
Criterion Conductive (ECF) Static-Dissipative (SD) What to Specify
System type Highly conductive epoxy or urethane with conductive fillers and copper grounding Static-dissipative epoxy or urethane with carbon pathways and grounding Call out resin chemistry, build thickness, and grounding detail at columns or walls
Resistance range (to ground) ~ 2.5×104 to 1×106 Ω ~ 1×106 to 1×109 Ω Align with device sensitivity and site policy. Tighter band for robotics and electronics assembly
Primary test methods ANSI/ESD STM7.1 Resistance of Floor Materials, ANSI/ESD STM97.1 System Resistance Person-Floor-Ground, ANSI/ESD STM97.2 Walking Voltage List required test methods in submittals and closeout
Typical environments Semiconductor, robotics, explosive atmospheres, data center UPS rooms Medical devices, pharma packaging, electronics labs, test areas Match to risk level. Conductive for highest control, SD for general ESD control
Grounding layout Copper tape grid bonded to substrate and tied to facility ground. Include ring terminals at perimeters and at least one connection per 1,000 to 2,000 sq ft, per manufacturer Detail grounding points on the drawings and in submittals
Footwear and chairs ESD footwear, heel straps, and ESD-safe casters recommended to meet STM97.1 and STM97.2 limits Include in owner responsibilities section and SOPs
Surface prep ICRI CSP 2 to 3 via diamond grinding or shot blasting. Moisture testing per ASTM F2170 for RH and F710 for pH Call out moisture mitigation when RH exceeds manufacturer limits
Installation stack Primer or MVB if required, conductive underlayer, copper grid, ESD body coat, optional ESD topcoat with wear additive Require wet mil or WFT checks and adhesion testing
Maintenance Neutral cleaner only, no acrylic floor finishes that insulate the surface. Periodic verification with resistance meter Add verification schedule to facility SOPs
Pros Fast charge decay, tight control for sensitive areas Broad compliance, easier fit for mixed-use spaces Choose based on device sensitivity and audit requirements
Watchouts May require tighter humidity control and stricter SOPs Too resistive for the most sensitive processes if not specified correctly Confirm limits with the site ESD coordinator before award
Notes: common spec ranges shown for guidance. Verify manufacturer data sheets and site ESD policy. Reference ANSI/ESD S20.20 program requirements and test methods STM7.1, STM97.1, STM97.2.

Epoxy is ideal where precision and aesthetics are key, while urethane excels in environments that combine static control with chemical or temperature exposure.

Installation and Grounding

Proper grounding is what makes an ESD floor functional. The process involves:

  1. Surface Preparation: Achieve correct CSP (typically 2–4) for adhesion.

  2. Primer Application: Promotes adhesion and seals pores.

  3. ESD Base Coat: Contains conductive fillers.

  4. Copper Ground Strips: Embedded beneath coating to connect to building ground.

  5. Topcoat: Provides durability, color, and consistent resistivity.

Grounding points are verified with resistance-to-ground testing to ensure compliance with ANSI/ESD S20.20 standards.

Common Mistakes to Avoid

  • Improper grounding — no physical connection to the building’s ground network.

  • Ignoring humidity control — static control depends on moisture balance.

  • Using incompatible cleaners — waxes and sealers can block conductivity.

  • Skipping performance testing — resistance testing ensures the system performs as specified.

At Surface Solutions, every ESD installation is verified with meter readings and documented resistance mapping for quality assurance.

The ROI of ESD Flooring

While ESD systems can cost slightly more upfront, their value is significant. Preventing just one incident of static discharge-related downtime often justifies the investment.

Benefits include:

  • Fewer damaged components

  • Improved operational safety

  • Compliance with ESD standards and audits

  • Increased equipment lifespan

For companies automating production or integrating robotics, the floor becomes part of the safety and performance infrastructure.

The Future: Smarter Floors for Smarter Facilities

As Industry 4.0 and smart manufacturing continue to evolve, the role of flooring will only grow. Static control, data transmission, and even embedded sensors are already shaping the next generation of industrial flooring technology.

Choosing an ESD-ready system today ensures your facility is prepared for tomorrow’s automation demands.

📞 Call 877-CSTM-FLR
📧 Email carolina@cstmflr.com

🌐 Visit www.cstmflr.com

Protect your people, your technology, and your productivity — from the ground up.

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