Types of Polyethylene Film Used in the Installation of Industrial Concrete Floors
Introduction
In industrial concrete floor construction, one often overlooked but critically important material is polyethylene film.
Acting as both a vapor barrier and a curing aid, polyethylene film plays a crucial role in maintaining the integrity, strength, and performance of concrete slabs.
Whether you're installing a new warehouse floor, manufacturing facility base, or commercial structure, understanding the various types of polyethylene films and their advantages will help you ensure long-lasting durability.
This article explores the main types of polyethylene films used in industrial concrete floor installation — from virgin polyethylene to recycled alternatives.
We'll also cover their function in moisture retention and their role in protecting concrete from rapid water loss during curing.
1. Virgin Polyethylene Film for Concrete Floor Installation
What is Virgin Polyethylene Film?
Virgin polyethylene film is manufactured using pure, high-quality polyethylene resin that has not been previously processed.
This results in a film that has excellent mechanical and chemical properties, making it the preferred material for industrial concrete flooring applications.
Characteristics of Virgin Polyethylene Film
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High tensile strength
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Excellent resistance to punctures and tears
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Superior moisture barrier properties
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UV stability (when required for exposed applications)
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Consistent thickness and quality
Applications in Industrial Concrete Flooring
Virgin polyethylene films are typically used under concrete slabs as a vapor barrier to:
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Prevent moisture from rising from the subbase.
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Improve concrete curing by reducing surface water evaporation.
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Protect the slab from chemicals and gases in the soil.
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Act as a separation layer between concrete and base material.
Recommended Thickness and Installation
Standard thickness for virgin polyethylene film in industrial concrete applications ranges from 150 to 300 microns (6 to 12 mil).
Installation involves overlapping joints by at least 10–15 cm and sealing them using specialized adhesive tapes to ensure a continuous barrier.
2. Recycled Polyethylene Film for Industrial Concrete Floors
What is Recycled Polyethylene Film?
Recycled polyethylene film is made from post-industrial or post-consumer recycled plastic.
While it may not offer the same level of consistency or performance as virgin film, it is a more sustainable and cost-effective solution for non-critical flooring applications.
Properties of Recycled Polyethylene Film
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Variable strength and flexibility depending on the source material
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Reduced cost compared to virgin film
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Environmental sustainability through waste reduction
When to Use Recycled Film
Recycled polyethylene film is suitable in situations where:
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Moisture protection is not the primary requirement.
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Budget constraints demand lower-cost materials.
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The project has a lower risk of chemical or gas exposure.
However, for large-scale industrial floors where structural integrity, moisture control, and durability are essential, virgin film remains the better choice.
Potential Limitations
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Inconsistent thickness and strength
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Higher risk of tears or punctures
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May degrade more quickly, especially under UV exposure
Contractors should evaluate recycled film carefully and conduct quality checks before use.
3. The Advantage of Using Polyethylene Film Under Concrete Floors
Polyethylene film serves multiple roles in the construction of industrial concrete floors.
Its versatility and effectiveness have made it a standard component of floor systems in warehouses, manufacturing plants, and commercial spaces.
3.1 Moisture Control and Vapor Barrier
The primary function of polyethylene film in concrete floor systems is to act as a vapor barrier.
Moisture from the soil or subgrade can rise through capillary action and impact the concrete floor, leading to:
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Efflorescence and staining
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Surface delamination
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Damage to adhesives or floor finishes
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Mold growth in overlaid flooring systems
A properly installed polyethylene film effectively blocks moisture movement, protecting both the concrete and any subsequent floor coverings.
3.2 Retaining Moisture for Proper Curing
Concrete must retain moisture for a sufficient period to fully hydrate and achieve its intended strength.
Polyethylene film helps in this process by covering the fresh slab and minimizing water loss due to evaporation.
Benefits of proper curing include:
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Increased surface strength and durability
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Reduced cracking and shrinkage
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Improved wear resistance
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Longer life span of the floor system
Especially in hot or windy environments, the use of polyethylene film is crucial for curing performance.
3.3 Separation Layer for Multi-Layer Floor Systems
In industrial settings where additional floor layers such as toppings, self-leveling screeds, or polymer coatings are applied, polyethylene film can act as a separation or slip sheet.
This helps:
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Prevent bonding between incompatible materials
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Allow controlled movement between layers
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Reduce stress transmission to the upper layers
This is particularly important in flooring systems subject to thermal changes or mechanical loading.
4. Selecting the Right Polyethylene Film for Industrial Floors
When choosing a polyethylene film for industrial concrete floor construction, several key factors should be considered:
4.1 Thickness and Durability
The film must be thick enough to resist tears and punctures during placement and concrete pouring.
For heavy-duty applications, 200–300 microns (8–12 mil) is generally recommended.
4.2 Moisture Permeability (Water Vapor Transmission Rate)
The film’s effectiveness as a vapor barrier depends on its permeability.
Look for products with low water vapor transmission rates (e.g., less than 0.1 perms) to ensure reliable moisture protection.
4.3 Chemical Resistance
In industrial environments, concrete slabs may come into contact with oils, solvents, or other chemicals.
A polyethylene film should offer high resistance to such substances to prevent degradation.
4.4 Environmental Considerations
Sustainability has become increasingly important in construction.
While virgin film offers optimal performance, recycled film can be used for projects prioritizing environmental responsibility, provided the quality is sufficient.
5. Installation Tips for Polyethylene Film Under Concrete Slabs
Proper installation is essential for achieving the desired performance from polyethylene film.
Here are some best practices:
5.1 Surface Preparation
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The subbase must be compacted and leveled before film installation.
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Remove sharp objects that could puncture the film.
5.2 Film Placement
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Roll out the polyethylene film over the prepared subgrade.
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Overlap seams by 100 to 150 mm (4–6 inches).
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Use specialized polyethylene seam tape to seal overlaps.
5.3 Reinforcement Considerations
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Ensure the reinforcement mesh or rebar is positioned above the film.
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Avoid dragging heavy materials across the film to prevent tears.
5.4 Pouring the Concrete
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Carefully pour concrete without displacing the film.
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Begin finishing only after the bleed water has evaporated and the surface is firm.
Proper attention during these steps helps maximize the performance of the vapor barrier and ensures long-lasting concrete strength.
6. Common Mistakes to Avoid When Using Polyethylene Film
Despite its simplicity, mistakes during installation can compromise the effectiveness of polyethylene film.
Avoid these pitfalls:
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Using thin or low-grade film that tears easily during placement.
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Failing to seal overlaps, which allows moisture intrusion.
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Installing over uneven or debris-filled subgrades, leading to punctures.
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Leaving gaps or unsealed penetrations, such as around columns or pipes.
Avoiding these errors is essential for achieving a high-performance concrete slab that meets industrial standards.
7. Comparison: Virgin vs. Recycled Polyethylene Film
| Feature | Virgin Polyethylene | Recycled Polyethylene |
|---|---|---|
| Strength | High | Moderate to Low |
| Moisture Barrier | Excellent | Moderate |
| Cost | Higher | Lower |
| Environmental Impact | Higher | Lower |
| Consistency | Excellent | Variable |
| UV Resistance | Good | Poor to Moderate |
The choice between the two types depends on the project’s performance requirements and budget.
Conclusion
Polyethylene film is a vital component in the construction of durable, high-performance industrial concrete floors.
Whether using virgin or recycled material, its primary functions — moisture control, surface protection, and curing support — play a major role in the success of flooring systems.
Selecting the appropriate type and installing it correctly ensures that concrete floors meet the rigorous demands of industrial use.
For projects where durability, longevity, and moisture resistance are critical, high-quality polyethylene films are not just recommended — they are essential.
By understanding the differences between virgin and recycled films, as well as their proper application, construction professionals can make informed decisions that enhance both the quality and life cycle of industrial flooring systems.
