Pharma manufacturer was setting up plants in a Special Economic Zone comprising of inhaler, liquids and tablet manufacturing. A total floor area of 12000 sqm was to be treated with aseptic flooring with cove bases and aseptic top coats for the coving conforming to clean room class requirements.

Working conditions consisted of raw material input, process rooms, office, packaging halls, finished goods storage areas, service floor and dispatch sections.

The requirement was to have a levelled surface with good abrasion, impact and chemical resistance to cleaning materials. The factory floor was to have clean room composite panel partitions with insulated doors and windows. The service floor required dust and maintenance activity resistant flooring.

The facility typically had core area surrounded by corridors facilitating man and material movement

Recommendations and installations were as follows:

• Process rooms, corridors: 5mm thick epoxy flooring with 3mm levelling underlayment made from 100% solid content epoxy and polyamide resin system and 2mm self-levelling cycloaliphatic amine based granolithic topping in approved shades.
3mm underlayment was completed first to start panelling activity followed by epoxy coving mortar installation followed by epoxy putty application.

Each panelled area was then topped with the epoxy based self-level granolithic flooring system and coving was finished with an aliphatic polyurethane top coat.

• Service floor: 1mm thick self-level epoxy flooring with 100% solid content and plain finish to take care of the dust proofing and maintenance activity working conditions.

• Service Floor: Electrical panel area: 3mm thick self-level epoxy flooring with di-electric properties to avoid electrical shock was installed in front of all major electrical panels on the service floor. This avoids rubber mats and thus contamination below the mats.