How often do you think about the floor in your cleanroom and controlled environment? Chances are it's quite often and changes in legislation - and maybe a change of production usage or methods - mean that floor finishes may have to be upgraded.
A new floor may be required to resist chemical or solvent spills or other risks of contamination. Or a change of usage could mean the floor has to be ESD to control static discharge.
Flooring experts can help with the specification process and will typically ask lots of questions before making any recommendations and developing the design.
Key considerations that should always be pointed out in the early stages of all potential projects include operational and maintenance requirements, installation and aesthetics - all of which are necessary to meet the stringent measures used to control particles to ultra-clean ISO standards.
Here are some of the most common questions and decisions that we ask to assess these and all of our healthcare and pharmaceutical clients during our initial meetings.
Meeting rigorous cleaning demands
To remove any spores in the air and to kill airborne germs, pharmaceutical sites tend to fumigate to control the microbial contamination in specialist areas.
This essential cleaning can be aggressive on certain floor finishes and vinyl. Certain epoxy and polyurethane systems are always recommended for these types of projects as they're more durable and better able to withstand the very rigorous demands of such processing facilities.
Chemical resistance
In many areas, chances are that the floor doesn't necessarily need to be chemically resistant, but there will be areas where it is extremely important.
Caustic solutions for CIP and solvents can seriously damage standard resin floors, which is why it's important to state what products are spilt - as well as their concentrations and temperatures - so that the correct level of protection can be specified. A lot of our systems can be enhanced with fiberglass reinforcement, which provides extra impact protection if required. Fiberglass reinforced "positive" side waterproofing membranes are another option to protect very important structural concrete floors or mezzanines, for example, from water ingress costs and associated costs.
Every flooring solution in cleanrooms and controlled environments should also be Current Good Manufacturing Practice (cGMP) compliant and installed using low Volatile Organic Compounds (VOC).
Current Good Manufacturing Practice is all about making sure that a facility is fit for purpose and will not pose a risk to the operation or the product. This is, of course, absolutely essential.
Seamless
Whether the floor can be seamless depends. If the structural floor slab has been designed to have some movement and has expansion joints, the answer is no. However, by using a "crack bridging" systems and full floor waterproofing layers with the appropriate final floor finishes, we're able to achieve a truly seamless floor.
Eliminating joints means there is less risk of the floor breaking down due to traffic and, very importantly, it reduces the opportunity for bacterial growth.
Making sure that there are only smooth surface transitions - as well as having mechanical protection of the floor and cove - is critical to protect against the more serious problem of bacterial infection in any of the transition points.
Is ESD flooring needed?
Some flooring solutions in pharma facilities need to be ESD rated - for instance, if solvents are being handled or there maybe nuisance dust to consider. Even the use of FLT's can generate very high levels of static that has to be controlled.
Within our range, we have numerous ESD flooring solutions to help control static. They can be decorative and even have enhanced chemical resistance.
Slip-resistance?
You don't want anyone to slip in your cleanroom, so make sure you specify textured, non-slip-resistant flooring solution.
It can be manufactured and installed in a variety of finishes and textures to help reduce slipperiness and increase traction. It goes without saying that it's extremely important when it comes to protecting employees, customers and visitors.
The look
You don't have to be restricted on choice of colours and decorative blends and finishes in a sterile environment. Select a manufacturer that can offer a wide enough selection to meet every aesthetic demand and, very importantly, all performance prerequisites.
Complementary drainage solutions?
We always recommend complementing sterile flooring systems with pharma-grade stainless-steel gullies and drainage solution from reputable, experienced manufacturers. Ideally, partner with a supplier that offers bespoke-manufactured products that are able to withstand the harsh cleaning regimes that such sterile environments demand.
Pharma-grade gullies should offer fully sealed tops that can be opened after specific spillages - that perhaps can't go straight to drain - so that they can be cleared away or neutralised.
Kerbs and walls
For the ultimate sterile and hygienic solution, we always recommend complementing seamless, non-porous flooring with prefabricated highly durable and water-resistant kerb and wall systems. There's been plenty of innovation in this space and a good flooring specialist will be able to supply the latest kerbs and wall systems to deliver maximum protection from water and germ infiltration.
Investment in this area will mean there are no cavities behind the skirting boards or kerbs, which means there’s no place for germs and bacteria to develop. Joints are finished with an advanced germ-free sanitary sealant and installation is quick and easy.
We also recommend to customers that walls are treated with a totally seamless and non-porous fibreglass reinforced resin system, which again are available in a wide range of colours, sheens and finishes. This is a hard-wearing coating that's able to withstand the rigours of high-pressure cleaning. It's also chemical and impact resistant, making it ideal for ultra-sterile environments.
Certification and quality
Another thing to look for is to a contractor who complies with all the necessary health and safety standards for both public and private sector contracts. A good supplier also needs to be experienced in managing a flooring project within the demands of a busy production environment. They should be able to minimise downtime by working weekends, nights and during shutdowns. And by using the latest fast-curing, taint-free flooring solutions, it should be possible to return to normal working conditions quickly and cost-effectively, with minimal disruption. So let's take a look at some scenarios...
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