| Excessive deflection | A mismatch between panel construction, thickness, support centres and the declared load case. | Visible sag, bounce, cracked finish or changing joint levels. | Approved system drawing, support centres, load inputs and design responsibility before panel release. | Check level, movement and support contact during installation and service. | Escalate when movement, damage or the project limit is exceeded; the responsible designer decides isolation or replacement. |
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| Local crushing from point or wheel loads | Small contact areas, turning wheels or outriggers overload the panel or support interface. | Dents, crushed overlay, soft spots, fastener dish or local core damage. | Provide wheel/contact geometry, dynamic case, load path and local support details. | Inspect known turning, braking, outrigger and transfer zones. | Isolate a locally damaged panel when integrity, surface continuity or fixing retention is uncertain. |
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| Unsupported joints or edge breakage | A panel seam or cut edge falls between supports or has inadequate bearing. | Stepped joint, chipped edge, flexing seam or split face around the joint. | Place every joint on an adequate support and coordinate openings before cutting. | Verify joint-to-support alignment before fixing and after module assembly. | Replace the panel or introduce an approved support change when bearing falls outside the project requirement. |
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| Fastener loosening, pull-through or raised heads | Wrong fastener/head, poor edge distance, moving substrate, over-driving or repeated vibration. | Proud head, enlarged hole, fretting, loose panel or pull-through dish. | System-specific fastener, head, pilot, edge-distance and substrate option. | Record head condition, movement and hole damage at service checks. | Use the approved repair detail, with panel replacement when hole or core condition falls outside the connection requirement. |
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| Water entry and edge swelling | Unsealed cuts, damaged edge coating, standing water, exposed holes or poor drainage. | Darkened edge, raised plies, swelling, coating cracks or joint misalignment. | Seal factory edges and reseal site cuts/holes; detail drainage and underside ventilation. | Inspect perimeter, penetrations, low points and cut-outs after wet exposure. | Isolate when swelling changes level, fixing retention or structural condition beyond the project acceptance rule. |
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| Overlay wear, damage or separation | Abrasive traffic, incompatible cleaning, impact, moisture entry or substrate movement. | Polished path, exposed substrate, tear, blister, lifting or local delamination. | Match overlay and substrate to traffic, contamination and cleaning; protect panels before installation. | Compare wear zones with the approved reference and record local damage. | Renew or replace when the surface options, substrate protection or project acceptance requirement is no longer met. |
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| Grip loss from wear or contamination | Water, oil, grease, mud, dust, aggregate or residue changes contact at the surface. | Visible film, packed tread, polished traffic line or cleaning residue. | Define expected contaminants, drainage, cleaning process and relevant test condition. | Inspect and, where required, re-evaluate the actual service condition alongside the new-surface reference. | Escalate after cleaning when the measured surface outcome remains outside the project requirement. |
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| Trip edge at joints, transitions or damaged panels | Differential movement, poor transition detail, swelling, loose fixing or impact damage. | Raised lip, widened gap, loose nosing or abrupt height change. | Coordinate joint support, tolerances, nosing, thresholds, drainage and replaceable-panel geometry. | Walk the option and check transitions under the operating condition. | Isolate promptly when the edge creates an unacceptable access hazard; repair or replace to the approved detail. |
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| Handling or packing damage before installation | Wet packs, uneven support, strap damage, forklift impact or dragging panels. | Bent corners, crushed edge, face scoring, pack distortion or moisture staining. | Use dry level supports, protected corners, controlled straps and written lifting and handling points. | Compare arrival condition with the reference before panels enter fabrication. | Segregate visible damage before fabrication and agree the repair or replacement option. |
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