Custom Rigid Core SPC Luxury Vinyl Flooring Supplier

Rigid core SPC (stone polymer composite) luxury vinyl flooring combines a dense limestone‑based core with a wear‑resistant vinyl top layer. The core provides dimensional stability under temperature fluctuations, while the wear layer protects against scratches and stains. This construction enables the product to meet the performance demands of commercial interiors where heavy foot traffic and moisture exposure are common.

Technical Specifications

Material Composition

The core consists of approximately 60 % calcium carbonate, 30 % polyvinyl chloride, and 10 % plasticizers and stabilizers. This ratio yields a rigid yet slightly flexible board that resists indentation from point loads. The wear layer is a clear polyurethane‑coated vinyl film whose thickness directly influences abrasion resistance; a 0.5 mm layer typically achieves a Taber abrasion loss of less than 80 mg after 1000 cycles.

Optional additives include antimicrobial agents (e.g., silver‑ion based) and UV stabilizers for areas exposed to direct sunlight. These additives are incorporated during extrusion and do not affect the core’s mechanical properties.

Manufacturing Process

Production begins with high‑speed extrusion of the SPC core, where the limestone‑PVC blend is heated to approximately 160 °C and formed into a continuous sheet. The sheet is then cooled, embossed with a surface texture, and laminated with the wear layer under calibrated pressure and temperature. Finally, the product is cut to length, milled with the locking profile, and subjected to inline inspection for thickness variance and surface defects.

Inline gauges monitor thickness tolerance within ±0.05 mm, while optical sensors detect surface irregularities greater than 0.1 mm depth. Any out‑of‑spec material is diverted to re‑grind, ensuring that only boards meeting the specified dimensional stability proceed to packaging.

Customization Options

• Overall thickness: 4.0 mm – 8.0 mm (step 0.5 mm)
• Wear layer thickness: 0.3 mm – 0.7 mm
• Surface finish: matte, satin, high‑gloss, or embossed wood/stones
• Edge profile: square, beveled, or micro‑bevel
• Locking mechanism: traditional click, drop‑lock, or adhesive‑free interlock
• Color palette: standard RAL shades or custom Pantone matches
• Additives: antimicrobial, UV stabilizer, flame retardant (halogen‑free)
• Packaging: shrink‑wrapped pallets, cartons with corner protectors, or reusable crates

Applications – Why the Product Fits

In healthcare facilities, the floor must resist frequent cleaning with disinfectants while maintaining slip resistance. The SPC core’s low water absorption (<0.02 % by weight) prevents swelling, and the polyurethane wear layer retains its coefficient of friction (>0.6) after exposure to hospital‑grade cleaners.

Educational buildings benefit from the product’s impact resistance; a 20 kg steel ball dropped from 1 mm height produces no visible dent on a 5.5 mm board with a 0.5 mm wear layer. This durability reduces lifecycle cost in high‑traffic corridors and multipurpose halls.

Retail environments require a floor that can tolerate rolling loads from pallet jacks and occasional point loads from display fixtures. The high core density (1.9 g/cm³) distributes loads, limiting localized deformation to under 0.1 mm under a 500 N point load, as measured per ASTM F970.

Quality Control Philosophy

Quality assurance follows a three‑tier approach: incoming raw material verification, in‑process monitoring, and final product testing. Each batch of limestone and PVC is accompanied by a certificate of analysis confirming calcium carbonate purity (>98 %) and K‑value of the PVC resin. During extrusion, laser‑based thickness scanners feed data to a statistical process control chart; any drift beyond 2σ triggers an automatic adjustment of the die gap.

Finished boards undergo a battery of tests: abrasion resistance (Taber), chemical resistance (ISO 26987), dimensional stability (ISO 23999), and load bearing (ASTM F970). Results are logged against specification limits, and a batch release certificate is generated only when all parameters pass. This systematic method reduces the risk of field failures and supports traceability from raw material to installation site.

Packaging & Shipping

Boards are stacked in layers separated by polyethylene sheets to prevent surface abrasion. Each stack is secured with polyester strapping and placed on a pallet that meets ISPM‑15 standards for export. Corner protectors made of recycled polyethylene are added to mitigate impact during handling.

For overseas shipments, the palletized load is wrapped in a UV‑stabilized stretch film and enclosed in a corrugated cardboard sleeve. This double barrier limits moisture ingress and protects against edge damage. Typical container utilization allows 22 pallets per 40‑ft high‑cube unit, translating to approximately 550 m² of flooring per container.

Frequently Asked Questions

Can dimensions be customized?

Yes. Thickness, width, and length can be adjusted according to project requirements. Custom widths typically range from 100 mm to 300 mm, while lengths can be produced up to 2.5 m without compromising locking integrity.

What information is required before quotation?

To generate an accurate quote we need the desired total thickness, wear layer thickness, surface finish, order quantity, delivery destination, and any required additives (e.g., antimicrobial). Providing the intended application helps us recommend suitable specifications.

How is quality inspected?

Inspection includes dimensional checks (thickness, width, length), surface defect analysis (scratches, embossing fidelity), and mechanical tests (abrasion, impact, dimensional stability). All inspections follow ISO 9001‑aligned procedures and results are documented in a batch test report.

What packaging methods are available?

Standard packaging uses shrink‑wrapped pallets with corner protectors. Alternative options include cardboard cartons with edge protection or reusable wooden crates for specialized handling requirements.

For technical data sheets, sample requests, or to discuss a custom specification, please reach out to our engineering team.