In furniture manufacturing, the search for sustainable materials is a constant challenge. One promising material that is becoming increasingly important in this sector is the recycled polyurethane panel (recycled PU panel). These panels offer an environmentally friendly and cost-effective solution that also guarantees outstanding quality and durability.
Recycled PU panels are made from recycled polyurethane, a plastic material that is widely used in a variety of industries. Recycling this material means we use fewer raw materials and at the same time reduce the amount of waste that ends up in landfill. Recycled PU panels are therefore a sustainable choice – both environmentally and economically.
The properties of recycled PU panels make them an excellent material for furniture components. They are extremely robust and durable, which means that furniture made from these panels can easily withstand daily, even intensive, use, and last for many years. They are also resistant to moisture, mould and insects, making them an ideal choice for kitchens, bathrooms and other humid environments. Recycled PU panels are available in various thicknesses, with the thinnest panels measuring just 10 mm. There is plenty of scope for thicker versions, so appropriately manufactured furniture components can withstand high loads.
It is therefore hardly surprising that we constantly receive enquiries about the production and processing of composite components using recycled PU panels. At Toms Gerber GmbH, we press the PU panels, ensure that they are cut precisely to size, and shape and process the workpieces on the machining centre in 5 axes. This enables us to create a variety of shapes and designs to order, giving contract fitters, interior designers or kitchen fitters a high degree of flexibility when producing customised furniture.
Recycled PU panels have a high number of potential applications. They can be used for a range of furniture components, including kitchen furniture (such as kitchen worktops with flush-mounted fixtures), outdoor kitchens and bathroom or patio furniture. They are also increasingly being used in the manufacture of table tops, shelves and cupboard doors. Particularly noteworthy is the waterproof bonding we use at Toms Gerber GmbH ensure in order to optimise the boards for wet areas.
Recycled PU panels make excellent workpieces for manufacturing furniture components due to their robustness, versatility and environmental friendliness. They offer a sustainable and high-quality solution that meets the requirements of modern furniture production.
Versatile and robust: the recycled PU panel is a solution for demanding environments
In addition to wet areas such as bathrooms and kitchens, the commercial sector in particular has requirements that go beyond those of residential environments. We are thinking here of challenging environments that require more than just 100% water resistance. In these environments, the material used must be resistant to rot, chemicals and cleaning agents, cigarette burns, abrasion and scratches. A specific customer challenge, from several years ago, also required a slip-resistant and non-slip floor in line with DIN EN 51130 specifications that could also be categorised as a class A wet barefoot area under DIN EN 51097. Finding a solution to this problem became part of our company story for a considerable period of time and culminated in the development in-house of a floor based on a recycled PU panel.
Developed to meet the most demanding requirements, the flooring we named WARECO evolved out of a recycled PU panel and would prove to be the ideal solution for a variety of challenging environments. But we would like to shed some light on of this specialised panel origins first, before taking a look at some of the applications for it. The idea of developing WARECO flooring was born in industry. When fitting out construction containers, we repeatedly encountered the same problem: conventional chipboard was not sufficiently durable. It quickly showed signs of wear and tear, was rapidly affected by rot and had to be replaced on a regular basis. This led not only to increased costs, but also to unwanted downtime due to maintenance.
So why not develop a floor that was specially designed for challenging environments but offered the same processing options as engineered-wood component? A floor that was durable, robust and yet aesthetically pleasing? This is how the idea for WARECO flooring was born, with the recycled PU panel being the catalyst. However, it was a long road from the initial idea to the finished product, a road along which the team at Toms Gerber GmbH developed, rejected and constantly improved the product, bringing diligence, meticulousness and a sensitivity to customer needs. The result shows that it was worth the effort. Today, WARECO is a high-quality floor covering that can be used in a variety of challenging environments.
An in-house development by Toms Gerber GmbH, WARECO flooring has with all the sustainable properties and water-resistance of a recycled PU panel, with specific additional features that enhance its value. Moisture resistance, rot-proofing and thermal insulation are combined with robustness, high slip resistance and abrasion resistance, making WARECO flooring a unique product on the market. This, together with its resistance to cigarette burns, chemicals, cleaning agents and rot, makes it ideal for a wide range of industrial applications.
Evolution of the recycled-PU panel: what can WARECO flooring do?
Thanks to our expertise in producing engineered-wood components for interior design, we are familiar with the requirements for prefabricated furniture components as well as floor coverings, and with the challenges involved in selecting them. Customers in the industrial sector used to have to search long and hard to identify solutions that were durable and resource-saving, especially in challenging environments. We joined them in this search and developed a solution to the problem, based on the recycled PU panel. Its water resistance and excellent workability with wood processing machines were convincing arguments in its favour.
WARECO flooring – an attractive, durable, safe and adaptable floor covering – was developed to be a plastic composite panel with a special focus on challenging applications. Many hours of development and countless field tests later, we had arrived at a composite material; it was developed as a floor covering, but just like all recycled PU panels, today it is the perfect solution for a wide range of contexts. First, however, we would like to shed some light on its properties as a floor covering, because the history of its development makes WARECO flooring ideal for anyone looking for a robust, safe and versatile floor.
A. Use of WARECO flooring in construction and shipping containers
WARECO originated in the fitting out of construction and shipping containers. WARECO flooring is therefore ideal for mobile use in containers of all kinds; its water resistance makes it ideal for installation in working areas that are often wet. The tiles provide a durable surface and are resistant to wear, scratches and stains. WARECO flooring is also non-slip, which improves safety in containers that are often used in harsh and changing environments. The flooring is uncomplicated to clean and its chemical resistance helps maintain its quality even when it comes into contact with harsh substances. It is therefore a practical solution that is ideal for use in containers.
B. Use of WARECO flooring in wet areas and leisure facilities
Another application for WARECO is wet areas in a wide variety of environments, including (mobile) sanitary facilities, and leisure facilities such as swimming pools, sports halls and gyms. Thanks to its special design and the mix of materials used, our flooring meets the requirements of assessment class A under DIN EN 51097, meaning it is waterproof and non-slip. It can also withstand high loads without wearing out. In addition, ease of cleaning and maintenance helps facilities to remain hygienic and free of dirt.
C. Installation of WARECO flooring in public places
WARECO flooring’s combination of aesthetics and functionality makes it ideal for use in challenging environments such as a hotel spas or wet areas on ships; its heat-insulating properties are particularly effective in these contexts and our waterproof bonding has many benefits.
It is available in a variety of attractive designs that emphasise the character of very different rooms. This is because WARECO flooring can be laid not only on floors; it can also be used for wet area walls, creating unusual décors such as a wood-effect shower. In spa areas, where water and moisture are omnipresent, slip resistance is also a key feature and significantly increases guest safety.
Installation of WARECO flooring
So whether you are designing hotel spas, private bathrooms or mobile sanitary areas, you can rely on WARECO for quality and reliability. WARECO flooring is not only robust and safe, but also practical. Another advantage of WARECO flooring is that it is easy to install. With a standard thickness of 21.6 mm, the panels weigh just 13 kg/m². Their modular design with milled tongue and groove joints allows for easy installation and makes laying the floor a simple and straightforward process. The modules are simply joined and glued together to create a seamless and robust floor while ensuring the specific properties are maintained over time.
For easy handling, we supply WARECO flooring with installation instructions. So you can be sure that installation will go smoothly and that you will enjoy your new floor for many years. The floor is laid dry, without moisture and long waiting times. The installation of WARECO flooring begins with preparation of the substructure. Permanently elastic spacers at least 2 mm in thickness are glued to the steel substructure at regular intervals. Continuous adhesive beading is then applied. We recommend specialist adhesives from Otto Chemie for this process. The WARECO panels themselves are pre-treated with an invisible release agent at the edges of the tongue and groove joints where they transition to the surface, in order to prevent any adhesive residue appearing at the joints when the panels are later joined.
The panels can now be laid. The floor panel is placed on the adhesive beading. The next step is to assemble the tongue and groove joints. It is important to apply a small but sufficient amount of translucent one-component PU adhesive to all connecting surfaces of the tongue and groove joint. The next panel is then placed in the adhesive bed and the joint is tightly closed. Any contaminants must be removed immediately with thinner. Once all panels have been joined together, the adhesive must cure for 24 hours. The final step is to remove or wipe away any excess adhesive from the joints using a spatula that will not damage the surface.
WARECO in summary: more than just a floor covering
When developing WARECO flooring, our focus from the outset was on versatility and resilience. On the one hand, the flooring can be used in a wide variety of construction environments; on the other hand, it is not limited to floors. As the example of spa resorts illustrates, WARECO can also be used for decorative walls in environments with challenging requirements.
This not only provides clients with highly functional interior components, it also opens up a wide range of design options. WARECO is an excellent choice for a variety of challenging environments due to its combination of water, slip and chemical resistance. Its robust design, durable quality and versatility make it a reliable and durable solution that meets the exacting demands of a wide range of sectors.
Wherever decorative qualities and the high-level functionality are required, WARECO offers a solution. Please contact us at by telephone or email to discuss your specific needs. We will be happy to advise you.