How plasticised PVC floors are produced

Manufacturers produce most PVC floors by a process known as 'plastisol spread coating'. In this, phthalates are essential to producing a liquid paste or 'plastisol', from solid PVC particles. The paste is applied in several layers so that the floor is literally 'built up'. Typically these include a foam core, a decorative layer and a clear protective wear layer.

Manufacturers use several different types of phthalate and each one has its own particular properties. Diisononyl phthalate (DINP), di-(2-ethylhexyl)phthalate (DEHP), benzylbutyl phthalate (BBP) and diisoheptyl phthalate (DIHP) are all used for floors.

Plastisols prepared with these phthalates are rapidly fused so that the layers can be applied at a high production rate. This ensures that the whole process is cost-effective. These plasticisers also enable the plastisols to be processed at a range of temperatures, while giving consistent, high quality foams. Thanks to these integral foams, soft PVC floorings deaden sound, have a pleasing softness under foot and yet are hard wearing.

Manufacturers can build up complex patterns and three-dimensional effects through these layers and offer more choice of styles and effects than would otherwise be possible. The end results are colourful, smooth and shiny surfaces that are modern and eye-catching.

Aesthetic value is not the only advantage of soft PVC floors. The smooth, tough surface of the upper wear layer prevents dust and dirt from building up and microbes breeding. In sensitive areas such as hospitals and clinics the hygienic quality of soft PVC reduces disease and infections. In the home, too, PVC floors in kitchens and bathrooms help to protect our health every day.

In ecological terms, the robust surfaces of soft PVC cut down the need for cleaning and the use of polish. They are a natural choice in schools, offices and public buildings with large floor areas, where robustness and low maintenance are vital.

PVC floors are outstandingly durable and typically last for up to 20 years of intensive use. Over all this time, despite large daily temperature changes, phthalates guarantee the flexibility of the application. They also resist degradation and discolouring from exposure to ultra violet (UV) light.