Using Kemlite Glasbord FRP for pharmaceutical Manufacturing Applications

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.

Providing a Safer Gym Locker Against Bacteria

antibacterialNew strains of MRSA, a drug-resistant bacteria, are emerging nationwide, causing hundreds of thousands of infections annually according to federal data, reports and academic studies. Though cases once were confined to hospitals, they are now showing up regularly in schools and gym locker rooms.

Formally known as methicillin-resistant Staphylococcus aureus, MRSA typically causes skin infections, from small pimples to painful boils, that usually can be treated effectively by doctors. In some cases, the infections advance, destroying tissue and causing large abscesses that can require hospitalization. And when staph enters the bloodstream or attacks the lungs as bacterial pneumonia, it becomes especially dangerous — often fatal. Federal data suggest that nearly 23,000 people die each year with MRSA infections.

Locker rooms are an ideal living environment for bacteria. Warm, humid, and moist environments encourage their growth and reproduction – See more here.

The CDC urges MRSA education and routine cleaning and disinfecting is recommended for lockers.

Tufftec athletic gym lockers are made of HDPE solid plastic which is a naturally germ resistant material. In addition, they are power washable and steam cleanable so there is no risk of rust or delamination therefore leaving a healthier environment for students. Because the material is a solid color throughout and not painted, a wide variety of cleaning solutions can be applied to the HDPE surface.

According to Sports Turf Northwest,, there are two ways to kill bacteria lurking on surfaces in a gym locker room that can cause MRSA and Staph. Harsh and toxic chemicals can be used, but will need to be used at least once a day with particular attention to sanitizing every locker room surface. A simpler and less toxic solution is ultra violet light technology (also called germicidal UVC). UVC is a special wavelength of light not visible to the human eye that penetrates the cell walls of microorganisms and destroys their ability to reproduce. Applying this light to your locker room surfaces is made easy with the miniZapr, made by Greensgroomer Worldwide. The miniZapr offers everything you need to eliminate harmful bacteria in locker rooms, on gym equipment, or community mats and other sports items. The miniZapr can be used just like a vacuum cleaner on floors or comes with a pull away germicidal UVC wand to sanitize tough to reach surfaces and small spaces. It is powered by either a small generator or you can plug it right into a wall outlet. Anyone can use the miniZapr, and it poses no health risk, unlike toxic chemicals, to patrons or staff. – See more here

Scranton Products has also tested their Tufftec athletic gym lockers with SiTU Bioscinces LLC by the ISO 22196 methods. The test results showed that after 24 hours, MRSA bacterial died off the surface of HDPE plastic without the use of any cleaning solutions.

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Get Serious About Health In Your Restrooms

antibacterialThere are many choices when choosing a material for your bathroom partitions. Though you may not be aware of it, many of the materials available for restroom partitions are not solid throughout meaning that the core is made from a particleboard or cardboard core. These cores are subject to mold,mildew and/or rust in a wet environment.

Hiny Hider partitions by Scranton Products are constructed from premium American-made 1″ solid High Density Polyethylene (HDPE) with a homogenous color throughout. The material resists dents, scratches, corrosion, graffiti and mildew – and will absolutely never rust.

This is especially important in restrooms because HDPE can be fully power washed and steam cleaned helping eliminate germs and bacteria that can feed in a restroom environment. The material is also impermeable to moisture and the non-porous surface does not support the growth of mold and mildew.

Because they never need painting, Hiny Hiders HDPE partitions deliver no VOC emissions and are Greenguard Gold Certified. It is important to look for this certification from manufactures because in an increasingly muddled green marketplace, GREENGUARD Certification provides an advantage by serving as a health-based differentiator. Products GREENGUARD Certified for low-chemical emissions can contribute to healthier indoor environments.

The HDPE material is also naturally germ resistant. Testing conducted by SiTU Bio sciences LLC. by ISO 22196 methods show that after 24 hours, 98.4% of MRSA bacteria died off the surface of HDPE plastic without the use of any cleaning solutions.

restroom_health

What’s the CORE Problem in Restrooms?

core_problem

There are many choices when choosing a material for your bathroom partitions. Before making a decision take a closer look at whats inside!

Material Options

The five main material options when choosing a bathroom partition are; Plastic laminate, Phenolic (black core), Stainless Steel, Baked Enamel, and Solid Plastic. All of these material choices vary in cost and have different cost of ownership models.

My Core is What?

Plastic laminate partitions are made from particle board and finished in a plastic laminate surface.

Phenolic (black core) partitions are compression molded; made from many layers of decorate papers which are saturated with phenolic resin. This forms the base which is then laminated with heat.

Stainless Steel partitions are generally manufacturered with a honey comb or wood core glued under pressure to #304 stainless steel sheets and assembled with roll formed molding.

Powder coated steel or baked enamel is a hybrid epoxy / polyester powder coated finished over galvanized steel is fabricated with roll formed molding and a honeycomb or woodcore.

Solid plastic is made from a polymer composed from extruded resin and is solid throughout.

How Cores Affect You

A source of potentially harmful air quality issues occur with exposure to mold, mildew and fungus.

Veneer exterior, particle board and honeycomb cardboard cores are at high risk for moisture penetration. This risk increases dramatically when these materials are placed in damp and wet environments such as shower rooms and restrooms.

Laminated or hollow core materials cannot be installed without penetrating the veneer exterior, exposing the interior to moisture and potentially water. This can create a harmful condition whereby the core of the partition becomes exposed to moisture while the thin veneer remains seemingly intact. As the core begins to mold and deteriorate, the integrity of both the air quality and partition structure are compromised.

This could result in an unforeseen hazardous and costly mold problem. This is particularly true in rooms with increased humidity such as showers, restrooms and locker rooms

Utilizing solid surfacing materials such as HDPE contributes to better indoor air quality as the solid, non-porous property of these materials resist the growth of mold and mildew.

Kingspan Insulated Metal Wall Panels

Kingspan currently offers a wide selection of metal panel wall systems to ensure every project has a cost effective and energy efficient solution. Because the path to a high performance building begins with a better building envelope, which offers healthier working environments, significant energy cost savings and a reduced carbon footprint. This is Kingspan’s design strategy, which is known as EnvelopeFirst™. It is also how you can enjoy energy efficiency and recognized ROI with the installation of these insulated metal panels. Superior in quality and durability, Kingspan’s insulated metal wall panels will offer superior R-values while providing a modern look for your building.

Whether the project requires acoustical, structural, or fire rated insulated panels, Kingspan insulated metal wall panels are the perfect solution to create and maintain a high performance building envelope. Take a look at a few of the benefits of working with Kingspan’s metal panel wall systems.

Insulated Metal Wall Panels Features 

  • High R-Value – Provides high thermal (R-value) and airtightness performance over the service life of the building. The insulated wall panels are exterior of the building structure to provide the best thermal envelope by reducing thermal bridging typical of cavity wall systems.
  • Tested & Approved – All insulated panels have been extensively tested for compliance with various industry standards and building safety codes.
  • Energy Efficiency – Insulated Metal Panels have a core of continuous, rigid insulation for industry leading R- and U- values with superior airtightness performance.
  • Indoor Environmental Quality – Insulated panels help ensure a stable interior environment.
  • Eased Construction – Insulated metal panels are simple to detail and attach, reducing schedules and installation errors.
  • Life-Cycled Benefits – Insulated Metal Panels last as long as the service life of a typical commercial building. The durable metal panels also reduce operational costs for energy maintenance and offer multiple end-of-life reuse options.
  • Building Certification and Green Targets – Insulated Panels contribute to LEED certification programs and the path to Net-Zero Energy.

RESISTALL PARTITIONS FROM SCRANTON PRODUCTS ARE BUILT TOUGH FOR BARS, CLUBS AND CAFÉS

resistall_partitionsResistall Partitions are made of HPDE plastic and are the perfect replacement for metal in tough environments like bars, clubs, diners, cafés and more. Resistall partitions are as tough as they are affordable and easy to install. Unlike metal, phenolic, stainless steel and other materials, they are highly resistant to dents, rust, scratches, odor, corrosion, impact and mildew.

For the establishment’s owner or property manager, Resistall saves on costly maintenance, with no need for painting or frequent repair and replacement.

Scranton Products, the nation’s leading manufacturer of plastic partitions for more than 25 years, designed Resistall to be impermeable to moisture, which can be a bathroom partition’s worst enemy, creating rust, mildew and a breeding ground for bacteria.

“In commercial applications where bathroom stalls take abuse, Resistall is the best value,” said Matt Keisling,Director of Sales, Scranton Products. “It stands up to attempted vandalism and rough handling with durable good looks,” he added. “Withstanding the test of time, Resistall can handle whatever patrons dish out.”

Made in the USA, Resistall partitions have gone head to head with metal in the most punishing lab tests-withstanding impacts of up to 500 lbs. from sledge hammers and scratches from razor knives. Resistall came through unmarred, whereas competitive materials suffered damage. And, Resistall’s unmatched 5-year warranty covers breakage, corrosion and delamination under normal conditions. The Resistall color selection includes Black, Grey, Beige and Linen.

Like all products produced by Scranton Products, Resistall is part of the company’s recycling program, which is committed to reducing industrial waste. All scrap and cut pieces are reclaimed and go back into the production of new HDPE sheets and contribute to LEED points.

Kingspan Cold Storage Insulated Wall Panels

Cold storage wall panels are a necessity when controlling a facility’s atmosphere is a must. When product protection and hygienic control are of utmost importance, cold storage panels will regulate when precise temperatures must be maintained. Climate controlled environments for food storage and cold freezers are perfectly suited as the tight fitting panel joints offer superior airtightness, preventing thermal bridging and condensation. Whether you are looking to control the temperature inside, or protect your product from the weather roaming on the outside, King-span Panels’ cold storage systems are the solution for you.

With multiple design options of cold storage walls, including Shadowline, A Azteco, Minor, In-verted, and High Rib profiles, Kingspan cold storage panels are the key to keeping both the temperature and your energy costs low. In respect to energy costs, cold storage wall systems provide optimal thermal insulation and can reduce HVAC / heating costs by up to 30% as you build a LEED certified facility. This is only a few of the many benefits demonstrated by King-span’s cold storage wall systems. Check out the full list of benefits our lineup of cold storage wall panels provide below.

Insulated Metal Wall Panels Features 

  • High R-Value – Provides high thermal (R-value) and airtightness performance over the service life of the building. The insulated wall panels are exterior of the building structure to provide the best thermal envelope by reducing thermal bridging typical of cavity wall systems.
  • Tested & Approved – All insulated panels have been extensively tested for compliance with various industry standards and building safety codes.
  • Energy Efficiency – Insulated Metal Panels have a core of continuous, rigid insulation for industry leading R- and U- values with superior airtightness performance.
  • Indoor Environmental Quality – Insulated panels help ensure a stable interior environment.
  • Eased Construction – Insulated metal panels are simple to detail and attach, reducing schedules and installation errors.
  • Life-Cycled Benefits – Insulated Metal Panels last as long as the service life of a typical commercial building. The durable metal panels also reduce operational costs for energy maintenance and offer multiple end-of-life reuse options.
  • Building Certification and Green Targets – Insulated Panels contribute to LEED certification programs and the path to Net-Zero Energy.

 

Commercial Restroom Trends

restroom_trends

Photo courtesy of U.S. News & World Report

What is the latest styles in commercial restrooms?  Upscale restrooms that contain high-end materials, commercial bathrooms that feel more like home, and design influences that match the environment around them are three trends you can expect.
Added sophistication – The words luxurious and sophisticated are rarely associated with public restrooms, until now. High end materials such as granite and stainless steel are making their way from the kitchen into the bathroom. This trend is not limited to residential applications. Hotels and other high end facilities are looking for ways to add that same level of sophistication to their public bathrooms. Materials like granite and stainless steel, or surfaces that look like granite and stainless, provide that luxurious feel they are looking for. Check out our designer, mosaic and metallic color series combined with our contour or rotary brushed textures and REGAL™ hinge to add some luxury and sophistication to your next bathroom project.

 

There’s no place like home – There is no place like your own private bathroom when it comes to “nature calling.” But, let’s face it, when you have to go, you have to go, even when you are far from home. A recent trend is creating a spa-like bathroom at home complete with a garden tub, massaging shower and soft lighting. Similar elements can make commercial restrooms feel more like home. In addition to using high-end materials, designers are replacing bright, fluorescent light fixtures with softer incandescent down lighting to create that spa-like atmosphere. They are also incorporating privacy features such as taller doors and privacy hinges. Try our zero sight continuous brackets, hinges and strikes to add privacy to your next restroom project.

 

Common theme all around – Designers are taking elements from the building’s interior design or the surrounding environment and carrying it into the restroom. This goes beyond the simple themed bathroom that pays homage to an era, famous person or pop culture icon. Examples include the public restroom in Bryant Park, New York that mimics the design of the nearby New York Public Library, the restrooms at Santa Monica Pier, California (pictured) that feature an undulating roof evoking thoughts of a vintage wooden roller coaster or the nearby ocean waves, or the bathroom at The Muse Hotel, New York that allows visitors to choose if they are feeling envious, passionate, glamorous, rebellious, macho or vain. What they all have in common is a uniqueness that is personal. To add uniqueness to your next project, ask for our custom embossing – perfect for a school mascot, company logo, or any other personalized detail.

Clean Room Case Study Using Kemlite Glasbord FRP

Construct a certified clean-room retrofit for medical product manufacturing with the following features:

  • Custom 14’ ceiling heights without horizontal seams
  • Highly reflective and cleanable seamless surfaces
  • Durable surfaces that resist damage from moisture, chemicals or cleaning agents
  • Cost effective long-term performance and no maintenance

The 23,000 sq. ft. space featured 14’ ceilings and wall substrates including plywood and drywall. The project plan called for FRP panels that would extend to the ceiling without horizontal seams. In addition to meeting clean-room certification, the client wanted seamless wall and ceiling surfaces for minimal maintenance, long-term performance, and ease in cleaning. 

FRP panels were the top consideration for construction, based on known performance characteristics, installation ease and long-term cost-effectiveness. Other potential options considered, but rejected included: lower-cost epoxy paint and/or silicone sealants, which would require ongoing maintenance and installation complexity.

SOLUTION

Crane Composites was selected based on three key factors:

  • Proven product quality, performance and installation ease
  • High levels of personalized service and hands-on product support
  • Ability for panel customization

OUTSTANDING PRODUCT PERFORMANCE

The solution for this clean-room was Glasbord panel, combined with Crane Fast Grab adhesive and Crane Polyurethane Seam Sealant, all independently tested and certified for cleanroom applications.

Glasbord with Surfaseal anti-microbial finish ensures that the surface will not trap soil or bacteria. Glasbord panels meet USDA/FSIS requirements. The Fast Grab solvent-free adhesive is formulated for superior panel adherence on plywood and drywall substrates.

Crane Seam Sealant is a fast-curing extremely low VOC urethane sealant specifically designed for seamless performance in clean-room applications. The two-part Seam Sealant bonds with Glasbord to create a monolithic surface for trim-free superior cleanability, low particle emission, biological and chemical resistance. The surface does not require maintenance and is particularly durable and resistant.

SERVICE AND SUPPORT

The client will realize long-term returns on its investment. The clean-room is built for durability, ease in cleaning and will remain virtually maintenance free for years to come. Additionally, the high surface reflectivity will help lower lighting costs over time.

CUSTOMIZATION 

For this project, the Crane Composites team was able to address the 14’ ceiling height and request for no horizontal seams by quickly supplying custom sized FRP panels. Glasbord FRP panels and all Crane Composites products, are produced at manufacturing facilities locally in the USA, so custom panels can be delivered on short-notice and cost-effectively.

BENEFITS 

  • Ease of FRP installation for labor cost savings
  • Glasbord meet USDA/FSIS requirements
  • Proven material properties and sealant that ensures virtually no maintenance
  • Seamless, monolithic wall panels do not produce or trap airborne particles
  • Superior chemical and biological resistance validated by independent lab tests
  • Smooth surface prevents buildup with superior cleanability
  • Documented extremely low VOC components
  • Significant cost savings in total installed cost versus alternative wall systems
  • Reduced installation complexity versus PVC and epoxy systems

 

Commercial Washrooms – Truly Sustainable Designs

In essence of the Greenbuild International Expo this week in New Orleans we feel that discussing sustainable material options for your restroom and locker room products are very important.

When you choose Scranton Products Hiny Hider Partitions, Resistall Partitions, Tufftec Lockers or Duralife Lockers you are supporting a healthier environment. Our products reduce industrial waste by using a blend of virgin and pre-consumer recycled content to produce a high quality product that is 100% recyclable.

sustainable_designGREENGUARD Gold Certified our products meet strict criteria intended for use in environments where children and adults spend significant periods of time. Because our products never need painting, they do not contribute to VOC emissions, which improves both indoor and outdoor air quality. In addition, they can be power-washed or steam cleaned, eliminating the need for harmful chemical cleaners. Incorporating our products can contribute points toward LEED certification as well. To learn more about Greenguard Certifications you can follow this link. Greenguard Certification

Scranton Products incorporates 25-100% pre-consumer content in all of our products allowing us to help achieve our goal of being a zero landfill facility and providing our customers with a greener solution to our materials. For those customers looking for a little bit more of a sustainable product we offer our Hiny Hider HDPE (high density polyethylene) partitions in 100% post consumer content. Our HDPE materials do not contain any added Urea-Formaldehyde resins and have an downstream process for recycling.