THE PROJECT
Headquartered in Dayton, New Jersey, Guardian Drug Company is one of the nation’s largest manufacturers of over-the-counter (OTC) pharmaceuticals. Guardian Drug Company’s customers include the nation’s leading drug store chains, mass merchandisers, supermarket chains, wholesalers and distributors.
The company required major construction over cinder-block walls for a clean-room area consisting of four chambers totaling more than 10,000 sq. ft. The space was to be used for product formulation and Packaging. General contractor for the project was Grad Industrial Works, Inc. of Sunnyside, New York.
THE CHALLENGE
Construct a suite of clean-rooms for pharmaceutical product formulation and packaging with the following features:
- Create smooth, easily cleanable surfaces in rooms with extensive piping, wiring and fixtures on wallsand ceilings
- Cover cinder-block walls for a durable, seamless, non-porous and moisture-resistant finish
- Enable high reflectivity on surfaces for brighter workspaces
- Ensure regulatory compliance and high sterile standards with low maintenance
The existing structure presented two potential options for the clean-room construction. Either frame the room with drywall and apply epoxy paint or utilize FRP panels. Given the extent of electrical boxes, piping and mounted equipment on the walls, labor costs would be excessive for drywall installation. Further, the painted drywall surfaces would require ongoing upkeep and maintenance.
SOLUTION
The choice for Crane Composites came down to these main factors that worked in favor of both the installer and the end-user:
- Proven Product Performance and Adaptability
- Immediate and Long-Term Cost Savings
- Customer Support and Service
PROVEN PRODUCT PERFORMANCE AND ADAPTABILITY
The Glasbord with Surfaseal anti-microbial finish provided a smooth, non-porous surface that is resistant to dirt and extremely easy to clean. The Advanced Polymer adhesive was integral to project success. Its ability to bond to any surface meant that the FRP could be applied directly over the cinder-block walls.
Specifically designed for seamless performance in cleanroom applications, Crane Seam Sealant is a fast-curing extremely low VOC urethane sealant. The Seam Sealant bonds with Glasbord to create a monolithic surface for trim-free, superior cleanability. The resulting surface created a strong and durable barrier to detrimental environmental conditions.
IMMEDIATE AND LONG-TERM COST SAVINGS
Unlike epoxy paint options, the Crane Composites cleanroom system creates a surface that requires virtually no ongoing upkeep, saving building owners significant maintenance costs over time. The surface is so durable that it can be cleaned easily, even with pressure washing. The highly reflective surface maximizes lighting in the room for brighter workspaces at lower costs.
Further, the system can create cleanrooms that are certifiable and compliant with increasingly stringent regulations, saving the risk of high-cost fines for noncompliance. Should it ever become necessary, panels can be replaced at a faction of the costs of other alternatives.
CUSTOMER SERVICE AND SUPPORT
Because Glasbord FRP panels, and all Crane products, are produced at manufacturing facilities locally in the USA, materials are delivered quickly and efficiently through a national network of highly knowledgeable distributors.
The Crane Composites team is constantly working with distributors, architects, contractors and end-users to offer hands-on support and training, with product knowledge and industry best-practices.
BENEFITS
- Adaptability of FRP panels to be cut, fit and sealed around complex fixtures and wall mounts
- Ease of panel installation directly on any surface using Advanced Polymer
- Proven material properties and sealant that ensures no maintenance
- Glasbord Surfaseal panels deliver extra-long life and performance
- Superior cleanability, even using pressure-washing
- Highly reflective smooth surface helps lower lighting costs
- Documented extremely low VOC components
- Significant immediate and long-term cost savings
- Reduced installation complexity versus PVC and epoxy systems.