In the realm of commercial safety, one hazard often underestimated yet fraught with substantial implications is the risk of slip and fall accidents. Statistics unveil a sobering reality: Slip, trip, and fall incidents account for a significant proportion of workplace injuries, marking them as a primary concern for occupational safety.
The U.S. Centers for Disease Control and Prevention (CDC) has reported an estimated 584,200 nonfatal, work-related slips, trips, and falls that occurred on the same level and resulted in hospital emergency rooms visits from 2020 to 2022.
The financial ramifications of these accidents are staggering. According to the 2022 Liberty Mutual Workplace Safety Index (WSI), falls on the same level have a financial impact of $10.26 billion annually. This link between the frequency of incidents and the consequent medical costs and legal fees, as well as productivity losses, underscores the critical importance of implementing preventive strategies.
Enter the technological safeguard: commercial anti-slip coatings. These coatings are not merely an accessory; they are an essential line of defense against the peril of slips and falls. By providing a higher traction surface, they significantly reduce the likelihood of accidents in areas prone to wet or slippery conditions.
Asphalt, wood, concrete, and steel are all traveled surfaces that can benefit from additional traction.
The Genesis and Evolution of Anti-Slip Coatings
Anti-slip coatings have their origins in the quest for safer industrial and commercial environments. Initially rudimentary in design, these solutions have evolved through rigorous research and innovation. Manufacturers have refined the composition and application methods to enhance durability, effectiveness, and ease of use.
Beyond bright attention-grabbing colors, early versions comprised simple grit additives, like sand, broadcast into floor paints. Also common were bright, aggressively textured, tapes.
While some of these legacy materials are still manufactured, today’s formulations of coatings maintain the wide variety of colors but are sophisticated systems incorporating advanced polymers, metal alloys, and epoxy resins engineered to achieve optimal friction levels for the desired application.
The evolution of anti-slip technology mirrors advancements in material science, with manufacturers leveraging composite materials to create coatings that are not only effective in preventing slips but also resilient against wear, chemicals, and environmental conditions. This progression has enabled the creation of products tailored to specific needs.
GacoFloor, the world’s leading manufacturer of anti-slip coatings, engineers products for toughness and durability across a wide range of applications. The GacoFloor portfolio includes AS-175 for barefoot areas like pool decks and water parks, offering a non-slip, easy-to-clean surface.
For residential and commercial light-duty use, AS-150 provides robust chemical resistance, while AS-75 delivers a weather-resistant, anti-slip surface ideal for asphalt.
In heavy-duty industrial settings, AS-2500 and AS-250 offer maximum durability, with AS-2500 being ideal for odor-sensitive environments and AS-250, enhanced with Kevlar, perfect for high-traffic areas like loading docks and ramps. 
Material Science at Play: Composition and Application
The efficacy of anti-slip coatings is contingent on their composition and the application process. At the heart of these products are materials designed to enhance surface friction. For instance, aluminum oxide, silica sands, and polymer beads are commonly used as abrasive additives to provide the necessary grip.
When the highest levels of traction are needed, some manufacturers can modify the aggregate by using angular aluminum oxide for additional abrasion in the resulting coating as opposed to smooth beads. The chosen aggregates are suspended in a binder — typically a resin such as epoxy or acrylic — that adheres to the flooring surface, creating a rugged texture.
The strength and longevity of the coating are significantly enhanced by the suspension of the aggregate within the resin. Over the years, as the surface layer wears away, the underlying aggregate becomes exposed yet continues to offer slip resistance due to its enduring adherence to the surrounding resin and thickness of the overall layer.
While coatings will eventually require reapplication, advancements in formulation technologies have significantly reduced downtime, enabling a rapid return to service — sometimes in just three hours, depending on the type of coating and its specific application.
Applying anti-slip coatings is generally straightforward, yet it demands careful consideration of the surrounding environment, especially in terms of temperature and moisture. The ideal temperature for application falls between 50°F and 90°F (10°C to 32°C), with deviations affecting the cure time.
Colder temperatures take longer to cure, but once cured, the performance characteristics are locked in. To mitigate the limitations imposed by seasonal low temperatures, some manufacturers have formulated coatings and application methods that are specific to lower temperatures.
However, it remains crucial to avoid applying anti-slip coatings during periods of high humidity or wet conditions no matter the season, as moisture can adversely affect the coating’s curing process and final quality.
Catering to Varied Applications: From Bare Feet to Heavy Vehicles
The diverse requirements for slip resistance across various settings have led to specialized coatings for particular uses. For locations frequented barefoot, like swimming pools, water parks, and locker rooms, there's a preference for coatings that balance safety with comfort. These areas benefit from coatings that incorporate a smaller, more rounded aggregate in less dense coverage, providing a gentler texture underfoot.
In commercial and residential spaces, the emphasis shifts toward medium-duty coatings that marry aesthetics with functionality, making them easy to clean while ensuring safety. These environments might see the use of aluminum oxide with a denser layering of aggregates to achieve this balance.
In very high traffic areas, coating in this category may offer the addition of advanced polymers to help with abrasion resistance. On the high end of the spectrum, industrial settings demand heavy-duty coatings capable of enduring the rigors of boot traffic, machinery, vehicles, and the corrosive effects of chemicals and oils.
To meet these challenges head-on, some formulas are bolstered with a combination of materials like Kevlar alongside angular aluminum oxide, offering unmatched durability and resistance to impact and abrasion.
Coating technology has expanded beyond mere anti-slip applications to include military-grade anti-skid solutions, now utilized in some of the most demanding environments such as on aircraft carrier decks. Some manufacturers are leveraging this advanced technology to offer a range of applications; from flight decks to factory floors, there is a coating to fit the need.
Durability remains a crucial factor in all categories, with the expectation that coatings will sustain their performance for several years. Advances in material science have facilitated the incorporation of ultraviolet (UV) stabilizers and wear-resistant additives to extend the lifespan of these coatings, even under conditions as harsh as the sunbaked concrete and heavy chlorine laden water of waterparks.
Conversely, in sensitive environments where health and safety are paramount, such as food preparation and packaging areas, the demand for anti-slip coatings extends beyond mere slip resistance and durability. These settings, sensitive to volatile organic compounds (VOCs), necessitate coatings that adhere to stringent health standards.
To ensure compliance, these formulations undergo rigorous testing to achieve certifications as Low VOC and Food Safe. This ensures they contribute neither to air quality degradation nor pose risks in food-contact scenarios.
The Confluence of Safety and Innovation
The importance of anti-slip coatings extends beyond their functional role in preventing accidents. They represent a confluence of safety, innovation, and commitment to protecting individuals in their workplaces and public spaces. By integrating advanced materials and application techniques, manufacturers have elevated these coatings from a mere safety measure to a sophisticated solution that addresses the nuanced demands of a wide range of environments.
In closing, the narrative of anti-slip coatings is one of continuous improvement and adaptation. Coatings have truly become a material science. Architects and specifiers should consider the history and current technology involved in anti-slip coatings.
It is worth understanding that it’s no longer a simple call out on construction drawings, and time should be taken to specify the correct, specifically innovated product for the application.
The complexities of maintaining safe public, commercial, and industrial spaces will benefit from the evolution of these coatings in our pursuit of safety. The journey from rudimentary grit-painted floors to advanced, durable coatings is not just a story of technological advancement, but a narrative underscored by a fundamental principle: the unyielding commitment to safeguarding human life in every step we take.
Editor’s note: This article first appeared in the January 2025 print issue of CoatingsPro Magazine. Reprinted with permission.
Jay Saldana, P.E. is the Principal Building Scientist for Holcim's Building Envelope division.