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Clean Room Flooring

A pharmaceutical concern located in New Jersey needed a cleanroom flooring system for their medicinal compounding

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Existing Conditions: This job was for a clean room in a pharmaceutical compounding facility in New Providence NJ.  In short, a compounding facility is where a licensed pharmacist, combines, mixes, or alters ingredients of a drug to create a medication tailored to the needs of an individual patient. That being said it was imperative this floor was as sterile as possible and met any ISO cleanroom standards, upon visual inspection, we determined an elastomeric floor coating was not required, this meant there could be absolutely no cracks or crevices which would allow dust and microbes to grow and spread, which would contaminate the room.​

Preparation of Existing Conditions: We began the prep phase by diamond grinding the entire substrate to remove surface contaminants and create a mechanical profile.

Next, our team installed keyways at all terminations to ensure system thickness while meeting termination elevations.

Once the keyways were complete the entire space was vacuumed and solvent wiped to remove any dust particles. This step is crucial, as any debris will prevent the epoxy coating system from adhering to the substrate. The final step was to apply tape lines on the walls at 4” heights to make sure we have the correct elevation on our cove base and to prevent any material splatters on the wall.

Products Installed: To guarantee our cove base mortar would adhere to the wall we first applied a primer to all of the walls. Next, we applied cove mortar to create a radial cove base with a 4” height and a ¾” radius. To remove any imperfections in the cove base we then stoned the entire surface. 

Before

Here is the floor before we install a cleanroom flooring system.

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During

Here is the floor with the base coat and radius cove base creating a bathtub effect minimizing any place for bacteria harboring.

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After

Here is the finished cleanroom flooring system, please note the smooth texture minimizing any concerns for bacteria entrapment etc.

clean room flooring-3

After the cove base, we began installing the resinous flooring system. For the first part of the system, we used it as a standard epoxy primer. It has good blush resistance and is low in viscosity to promote good penetration of the concrete substrate. Next, we made an epoxy slurry. We applied this batter like epoxy resin using a v-notched squeegee to a thickness of 1/16”. Epoxy was the perfect material for this clean room because it is self-leveling, thus ensuring a smooth floor, and has antimicrobial properties. Finally, we applied a water-based top coat of water-based urethane. It was chosen because of its excellent resistance to pharmaceutical chemicals.

 

Conclusion: This floor needed to be as sterile as possible and meet any ISO cleanroom standards. This meant there could be absolutely no crack or crevices which would allow dust and microbes to grow/spread and would contaminate the room. This makes seamless flooring the best application when dealing with a cleanroom.

Clean rooms are found in a variety of facilities that service the pharmaceutical, vaccine, and biotechnology industries, to name a few.

As a part of our free consultation, we determine the right epoxy flooring system for the right situation as example we would specify a hangar flooring system or anything that texture might trap dirt and bacteria.