Polyurethane Heavy Duty Mud Flaps: Built to Last

When it comes to heavy-duty vehicles like lorries and diggers, protecting them from road debris and reducing spray is crucial. Heavy-duty mud flaps play a vital role in safeguarding both the vehicle and other road users.

Mud flaps serve a multitude of purposes and face considerable wear and tear on commercial vehicles. Specifying polyurethane products optimises their advantages and durability. But why is polyurethane the best material for your custom mud flaps?

Polyurethane is the ‘go-to’ solution for a growing list of standard automotive parts and components. The team at Custom Moulded Polyurethane is also increasingly asked to innovate and create bespoke parts for vehicles of all shapes and sizes.

However, there is one fundamental feature of vehicles that have been relying on the unique properties of polyurethane for some time. Whether it’s for a tractor, HGV lorry, trailer, bicycle or even a high-end car, there are strong reasons to specify polyurethane mud flaps.

Quick reminder – what is polyurethane?

Polyurethane flaps are used not just to protect vehicle bodywork from damage. For example, pliable curtains made from this material are ideal for conveyor systems, though polyurethane is also used for heavy-duty rollers in production lines too

That’s because polyurethane can be manufactured to perform a highly diverse range of functions. This incredible versatility comes from its chemical formula. A polyol (organic compound) with multiple reactive hydroxyl groups is blended with a polymeric isocyanate. This creates a chain reaction, resulting in substance with tightly bonded molecules.

By varying the catalysts and other additives, you can produce polyurethane as an adhesive, liquid, foam or even a block with the tensile strength of metal.

The many advantages of polyurethane

The above outline illustrates that polyurethane mud flaps are formulated to perform brilliantly, but also to outlast their ‘rivals’. The mix dictates the perfect tensile spec, then the moulding process shapes this resilient and durable material into any conceivable form, including intricate detailing and complex contours.

This means, for instance, if you want a logo on a polyurethane mud flap, it is easy and cheap to achieve.

When developing a new vehicle or replacing parts on an existing one, you can specify whether you need a rigid or pliable flap or mud flaps with smooth or textured surfaces. Do you want a thicker or thinner than normal flap? A flawless outcome is guaranteed with high-performance polyurethane.

What about performance though?

Creating an effective barrier

Both universal and custom mud flaps do far more than act as wheel-spray guards. They also prevent a diverse list of pollutants – and potentially corrosive substances like salt – from getting to your bodywork. Heavy-duty commercial vehicle mud flaps stop small stones and other debris from creating damage. Some flaps on wheel arches are designed to reduce the risk of mud spray obscuring the driver’s windows too.

Polyurethane is not only a mud flap material that outlasts its rivals, it is also the best choice for ensuring your vehicle can withstand all that the elements throw at it. For example, both rubber and plastic undergo structural alteration due to intense heat, and rubber can crack or flake due to cold weather. Polyurethane is impervious to even extreme temperatures.

Also, the grip on rubber and plastic changes when they are wet or greasy. Polyurethane mud flaps dispel all pollutants. They are also resistant to moulds and mildew, unlike many of their rubber counterparts.

Related article: How customised polyurethane moulding can help your business

Understanding Heavy-Duty Mud Flaps

Heavy-duty mud flaps are robust protective devices mounted behind the wheels of commercial vehicles to mitigate the impact of road debris and prevent mud and water from being flung onto surrounding vehicles and pedestrians.

These mud flaps are subject to harsh conditions, including extreme weather, debris impact, and continuous exposure to road contaminants.

To withstand these challenges, heavy-duty mud flaps are engineered using durable materials and thoughtful design. The choice of material plays a pivotal role in determining the performance and longevity of the mud flaps.

Related article: The advantages of Polyurethane for custom mud flaps

Materials for Heavy-Duty Mud Flaps

Various materials are used in the manufacturing of heavy-duty mud flaps, each offering different levels of durability and performance. Common materials include rubber, thermoplastics, and polyurethane.

Rubber Mud Flaps

Rubber is a popular choice for mud flaps due to its flexibility and affordability. While rubber offers decent durability, they tend to degrade over time under harsh conditions. They can become brittle, crack, and tear, leading to diminished protection and a shorter lifespan.

Thermoplastic Mud Flaps

Thermoplastics, such as polypropylene or polyethylene, are also commonly used for mud flaps. They provide good resistance to impact and weathering, but their performance can vary depending on the specific formulation and quality of the material.

Related article: Using polyurethane’s strength for custom mud flap design

Polyurethane benefits for flaps

We have explored the advantages of polyurethane for mud flaps elsewhere on this specialist PU website.

However, it’s worth just a quick reminder of why this material is increasingly used for mud flap designs.

Not only can polyurethane be created in ANY size or shape, but its tensile properties can also be varied in a vast number of ways. From heavy-duty flaps to protect large vehicles operating in challenging terrain, to soft, thin and highly flexible PU structures, that support intricate tasks where the lightest of touches is required.

This tensile customisation is possible without compromising polyurethane’s impressive durability. It is also the material of choice when you need a part resistant to extreme temperatures, oil, moulds, and a wide range of other contaminants.

Mudflap reliability

Many of the above maintenance issues for mud flaps are risks that develop over time. However, one of the most common perils for mud flaps in industrial applications is far more immediate and potentially dangerous.

If this part tears or splits suddenly, it fails to do its purpose. Meaning debris can reach the areas you are aiming to protect, causing damage and putting machinery and vehicle operators at risk.

This is when tensile strength values become crucial in creating custom mud flaps.

What is meant by made-to-order tensile strength, in specifying this crucial part for industrial machinery and vehicles?

The term clearly relates to how likely a material is to fall apart or become generally compromised when it encounters a force of some kind. Whether that is something pulling on it, or considerable abrasion or impact.

When creating a spec for mud flaps, you need to consider the dimensions and level of rigidity you need to ensure this item can be fitted seamlessly and carry out its role effectively. By working with a polyurethane specialist supplier on the tensile properties, you can take that process a step further. It enables you to be exacting on such issues as:

• Where and how it is fixed in place.
• How secure it will remain while in operation.
• How well it copes with drag or being trapped.
• Its ability to withstand impacts – such as hitting curbs, rocks, or stones.
• Its ability to withstand heavy-duty contaminants that would risk the integrity of alternative materials.

Related article: Heavy Duty Mud Flaps – Which material is the most durable

Polyurethane Maintenance advantages

By varying the tensile strength of custom-created mud flaps, you also get an opportunity to extend the life of this part. Polyurethane mixes can be created to offer impressive life cycles even for parts under constant pressure and challenge.

This means if you work with a polyurethane expert to pin down your ideal tensile value, you can reduce the number of times this part needs to be replaced. Your machinery or vehicle can be optimised, with less time out of use for repairs and regular maintenance tasks.

Related article: How customised polyurethane moulding can help your business

Made to order mud flaps

As mentioned above, the versatility of polyurethane makes it ideal when you have clear product specifications to meet. Combine that with our skills and experience in custom moulding and you can order mud flaps in any design, shape or colour you want.

Commercial mud flaps featuring branding are popular with transport organisations or any business with a fleet. Tailored mud flaps are supplied pre-drilled, so you can fit them to vehicles quickly and easily.

Despite the fact they are a superior vehicle accessory, you will still find custom mud flaps made from polyurethane a cost-effective option.

Also read: Why a ladder hook will last longer with polyurethane

Suppliers of universal and custom mud flaps

We also offer low-cost polyurethane mud flaps in standard forms of course, usually with rounded corners to boost performance. Though feel free to ask for a different shape

In fact, for polyurethane flaps for any purpose including the best vehicle mud flaps, give us a call to benefit from our fast and efficient customer service.

We are always happy to give you the ‘dirt’ on why our mud flaps are better than alternatives

Mud flap design help

Being exacting on the specifications for mud flap designs – including tensile strength values – can clearly be important. Does it mean compromising on the cost of these essential parts, or being ready to face longer lead times for delivery?

CMP ensures that neither of these concerns is an issue. We offer highly cost-effective custom mud flap design services, using our unrivaled expertise and specialist equipment to create the perfect product – delivered swiftly.

Final Words

When it comes to heavy-duty mud flaps for commercial vehicles, the choice of material is critical to ensure durability and long-lasting performance. While rubber and thermoplastic mud flaps offer certain benefits, polyurethane mud flaps emerge as the clear winner. With their unmatched durability, flexibility, resistance to environmental factors, and ease of maintenance, polyurethane mud flaps provide the utmost protection and longevity.

For commercial vehicles like lorries and diggers, investing in polyurethane mud flaps ensures optimal protection, reduced maintenance costs, and enhanced safety on the road.