Pharmaceutical Manufacturing Facility — Tema Industrial
Pharmaceutical manufacturing facility commission requiring 2400 sqm specification-grade industrial epoxy with ISO 14644 cleanroom adjacency + ESD-controlled assembly zones. Epoxy Flooring Ghana delivered substrate moisture remediation, FF50 floor flatness, and IEC 61340-5-1 grounding network with full commissioning test record.
Project Profile
Sector: Pharmaceutical Manufacturing Scale: 3,200 m² Scope: Full floor system specification, surface preparation, application, and commissioning Timeline: 14 working days — phased to maintain partial production continuity
A pharmaceutical manufacturer operating a large-scale production campus within Tema Industrial Zone required a complete floor system overhaul across its primary synthesis halls, cleanroom ante-chambers, and quality-control laboratory corridors. The facility operates under continuous production schedules, international GMP (Good Manufacturing Practice) certification requirements, and rigorous third-party audit protocols. Floor failure — chemical breach, surface delamination, or hygienic compromise — carried direct regulatory consequence.
Specification Challenge
Pharmaceutical manufacturing floors occupy a uniquely demanding position in the performance-flooring hierarchy. The surfaces in question faced simultaneous exposure to:
- Concentrated solvents and cleaning agents applied on daily sanitisation cycles
- Forklift and pallet-jack traffic across synthesis hall floors
- Cleanroom humidity gradients requiring moisture-vapour-tolerant systems
- Zero-tolerance contamination standards mandating seamless, cove-detailed floor-to-wall junctions
- An existing substrate compromised by previous coating delamination and micro-cracking from inadequate original specification
Critically, the client required phased handover: production in certain bays could not cease entirely for fourteen consecutive days. The project demanded precise sequencing to deliver compliant floors bay by bay while the facility remained operationally viable.
Approach
Our specialists conducted a full substrate assessment prior to specification finalisation — including moisture emission testing, surface tensile strength pull-off testing, and chemical exposure mapping by zone. This diagnostic stage prevented specification error and informed a differentiated system across zones.
Synthesis Halls: A high-build solvent-resistant epoxy topping at 4 mm nominal thickness, applied over a penetrating epoxy primer and reinforced screed where substrate void mapping indicated structural compromise.
Cleanroom Ante-Chambers: An electrostatic dissipative (ESD) epoxy system with continuous earthing strapping — eliminating static charge accumulation in environments handling sensitive active pharmaceutical ingredients.
Laboratory Corridors: A chemical-resistant polyurethane–epoxy hybrid at 3 mm, offering enhanced flexibility under thermal cycling from laboratory HVAC systems.
All junctions received 150 mm coving in matching system materials, eliminating the seam-lines that harbour microbial accumulation. Surface preparation across all zones was executed via diamond-head floor grinding to ICRI CSP-3 profile — the substrate condition required for system-grade adhesion at institutional specification.
Phased handover was delivered in five discrete bays, with each bay commissioned and returned to the client before the next was closed for works.
Outcome
- 3,200 m² of performance-engineered floor system delivered across three distinct zone specifications
- Full phased handover achieved within 14 working days — no production line fully offline at any single point
- Substrate voids and delamination zones fully remediated prior to topcoat application
- GMP audit-ready surface: seamless, coved, chemically resistant, and ESD-compliant in controlled zones
- Client’s quality assurance team confirmed floor system against specification prior to commissioning sign-off
What This Project Demonstrates
Pharmaceutical manufacturing is among the most specification-intensive sectors in the performance-flooring discipline. Surface failure is not a maintenance inconvenience — it is a regulatory and production-continuity crisis.
This project demonstrates the capacity to deliver differentiated, zone-specific floor systems within a live industrial facility, under schedule pressure, against international compliance benchmarks. It reflects 45 years of practice in Ghana’s most demanding institutional and industrial environments — and the kind of methodical, specification-first approach that Tier-1 manufacturing clients require when flooring failure is simply not an option.