As a refrigerated truck floor, why are XPS sandwich panels prone to cracking at the wheel path during forklift turns?

The root cause is the low shear fatigue strength of XPS foam, combined with the complex triaxial stress during forklift turns – vertical compression + horizontal shear + torsion. The critical shear strain of XPS is only about 2%, while PVC can reach 15%. Inspection of used truck floors revealed that after 10,000 passes of forklift wheels, the XPS core developed through-thickness cracks, followed by fatigue cracking of the facing. Improvement methods: 1) Use PET or PVC core; 2) Cover the XPS with a wear-resistant steel plate (thickness ≥2mm); 3) Design localized thickening or metal inserts at the wheel path. Codes require heavy-duty truck floor turning areas to have a service life of ≥5 years/1 million passes.

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As a refrigerated truck floor, why are XPS sandwich panels prone to cracking at the wheel path during forklift turns?

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