URBS (Urbanização de Curitiba S/A) is the department responsible for urban planning and maintenance in Curitiba, in southern Brazil. With 1.83 million inhabitants, the city is a South American pioneer in efficient public transport systems, utilizing high-traffic tube-style bus stations.
Challenged by high maintenance and downtime
Curitiba's iconic tube-style bus stations serve between 1,500 and 2,000 passengers per day. Historically, these facilities relied on external and internal flooring made of marine plywood and special rubber coatings, which were prone to moisture damage and rapid wear. The average time between major maintenance was only 12 to 18 months. Crucially, the floor renovation required a three-day station closure, resulting in significant operational disruptions and high labour costs. URBS required a modular, durable, and sustainable system that could handle heavy pedestrian traffic and align with its vision for more sustainable urban development.
Collaborative partnership to set new standards
Working closely with our key Brazilian partners: G12 Innovation, Loop Sistemas Sustentáveis, and OM Group, Diab was instrumental in helping URBS transition from vulnerable plywood overlays to an advanced, sandwich-concept composite floor panel. This collaborative approach, which integrated material science with local production expertise, was essential for designing a durable, high-performance solution capable of handling Curitiba's extreme foot traffic and aligning with the city's vision for sustainable urban modernization.
The final panel features a high-compressive-strength Diab Divinycell H60 core (25–30 mm thick, 60 kg/m³ density), specifically chosen for superior rigidity, weight reduction, and moisture resistance. This core is integrated with a high-abrasion gelcoat, fiberglass fabrics, and a high-performance post-consumer vegetable polyurethane resin for excellent impact and fatigue performance. Designed as modular panel kits, the entire system simplifies the installation process and features a non-slip black finish created directly in the mould.
Dramatic increase in performance and efficiency
After rigorous testing, including a 12-month pilot phase in a high-traffic bus station, the new composite flooring demonstrated a dramatic increase in performance and efficiency. The functional lifespan of the new flooring is estimated at over 5 years, a significant increase over the lifespan of the original product. Loop/Diab's modular, assembled panels allow for significantly faster installation, minimizing disruption to the route and drastically reducing maintenance costs. The composite structure further aligns with URBS's goal of utilizing more sustainable products, thanks to its inherent longevity and the use of a bio-based resin. Furthermore, the lightweight composite further reduces CO₂ emissions compared to the previous solution.
"We will have a lighter and more practical product, with low maintenance, a competitive total cost, and aligned with our vision of continuously integrating more environmentally friendly materials and products." – Alceu Portella, Maintenance Director, URBS.
With the approval of the successful pilot, the URBS project has the potential for large-scale implementation in the city's 400 to 500 bus stations, representing an estimated annual potential of 15,000 to 20,000 m² of advanced composite flooring.
