How Nuway Tuftiguard is made
Forbo Flooring Systems has been producing high-quality commercial flooring since 1847 and, for over a century, Nuway has been a prime choice for entrance flooring systems.
What is Nuway?
Nuway is our leading entrance flooring system that includes single and double-sided solutions. These systems provide the first line of defence against soil and moisture entering a building, collecting debris from the soles of shoes and the treads of wheeled traffic.
Nuway Tuftiguard is our primary barrier matting, offering outstanding defence against soil and moisture entering a building. It is available in both internal and external models.
As part of the 100 years of Nuway celebrations, we spotlight one of the best-selling entrance flooring systems from Forbo Flooring Systems: Nuway Tuftiguard.
Where is Nuway Tuftiguard made?
The entire Nuway Tuftiguard collection is manufactured in the UK in Telford, Shropshire. This includes:
• Nuway Tuftiguard
• Tuftiguard Heavy Duty
• Nuway Tuftiguard Bamboo
Each option is designed to handle various levels of usage intensity, point loading, installation/matwell environments, and existing cleaning regimes.
The factory also manufactures Nuway to coordinate with our Coral textile entrance systems, , to deliver integrated interiors for all customers.
Aside from Nuway Tuftiguard, all Nuway flooring ranges are also manufactured in Telford, including our other collections: Connect and Grid.
The Nuway Tuftiguard manufacturing process
1. Use of raw materials
Our factory in Telford uses a collection of raw materials to create the foundations of Nuway Tuftiguard. The process begins with a UK-manufactured rubber compound solution rolled over a nylon 6.6 cord, similar to how car tyres are made.
We also use extruded recycled aluminium profiles, with 30% sourced within the UK. To complete the foundations, we use UK-manufactured galvanised and stainless steel wire and PVC extrusions.
2. Rubber buffing
The rubber is cut into wiper strips and buffed, exposing the 95,000 nylon filaments per square inch. Each filament is dyed in one of the two available colour options, except for Classic, where the filaments remain undyed.
3. Rubber punching
Holes are punched into the material to facilitate the assembly of the flooring. The rubber is then cropped to the appropriate length.
4. Scraper bars
Depending on the materials used in the chosen Tuftiguard product; aluminium or Bamboo scraper bars, the material is sawn to the correct length, and the assembly holes are pressed.
5. Assembly
During the assembly process, the cut-to-length extrusions and rubber are joined together with steel wire. Each mat is hand-assembled according to the customer's specifications, using their chosen combinations of anodised aluminium or Bamboo or standard scraper bars, buffed or unbuffed prime rubber, and polyamide fibre composite wiper strips.
6. Shaping
The mats are then shaped to customer specifications or templates. For more complex installations, final finishing and shaping can take place on-site.
7. Sustainability
All steel and aluminium used in the process is recycled. Rubber pips are sent to crown bowling clubs for use in lining the gully, while other rubber waste is used in equestrian centres.
Most Tuftiguard barrier matting is also double-sided, helping extend the product's lifecycle when installed.
8. Delivery
For orders under 10m², we protect the edges of Nuway flooring with cardboard and wrap one or two sections at a time with bubble wrap. For orders over 10m² destined for the UK, Ireland, or Northern Europe, the product is shipped on a pallet.
Where has Nuway Tuftiguard been installed?
Nuway Tuftiguard has been installed in some of the most recognisable buildings in the UK. This includes:
Birmingham New Street Station
As part of the first phase of New Street Station’s redevelopment, Nuway Tuftiguard was installed to accommodate over 140,000 passengers a day while minimising the risk of slips and trips.
New Street Station, the busiest interchange station in the UK, required a heavy-duty entrance barrier matting system to remove dirt and moisture from the soles of shoes, protecting travellers from accidents and maintaining the interior floor coverings' appearance.
Nuway Tuftiguard was chosen for its durability and strength under heavy traffic conditions and its ability to remove high levels of soil with scraper bars and wiper strips.
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Heathrow Terminal 5
Over 33 million passengers walk through Terminal 5 each year, necessitating tough and resilient entrance flooring.
Nuway Tuftiguard HD entrance matting was extensively installed around the building’s doorways to scrape dirt and remove moisture, protecting the interior flooring and preventing slips, adhering to current health and safety standards.
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Benefits of Nuway Tuftiguard when installed
Nuway barrier matting is the most robust entrance flooring solution in the Forbo Flooring Systems collection, designed to welcome up to 100,000 visitors a day.
Nuway is guaranteed for up to 15 years when installed by a FESSI (Forbo Entrance System Specialised Installer). This extended guarantee is possible only through high-quality installation by one of our FESSI Contractors, based across the UK.
You can also get an extended guarantee on all commercial flooring from Forbo, if you purchase and install it alongside our entrance flooring. With our entrance flooring keeping dirt and moisture out, your internal flooring will be guaranteed for another 5 years on top of your initial 10-year guarantee.