Clean Room Flooring
Project Overview: Clean Room Flooring System – 572 sf. with 220 lf. of cove
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 and all ISO cleanroom standards. 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 coating system from adhering to the substrate. The final step was to make 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.
After the cove base, we began installing the flooring system. For the first part of the system, we used GP 3579 as a standard epoxy primer. GP 3579 has good blush resistance and is low in viscosity to promote good penetration of the concrete substrate. Next, we made a slurry mix of Trafficote 105. We applied this material using a v-notched squeegee to a thickness of 1/16”. Trafficote 105 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 urethane topcoat of GP 4410. GP 4410 was chosen because of its excellent resistance to pharmaceutical chemicals.
Conclusion: It was imperative for this floor to be as sterile as possible and meet any and all 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.