Pharmaceutical Manufacturing Facility, Tema Industrial Corridor
Specification-grade industrial epoxy and anti-static ESD flooring across a pharmaceutical manufacturing facility in Tema's industrial corridor. Substrate moisture remediation, IEC 61340-5-1 grounding network, and ISO 14644 cleanroom-adjacency compliance documented across the full programme.
Project Profile
| Field | Detail |
|---|---|
| Sector | Pharmaceutical Manufacturing |
| Scale | 2,400 sqm across active production halls, ESD-controlled assembly zones, and pharmacy dispensary spaces |
| Scope | Substrate moisture remediation, self-levelling compound underlay, specification-grade industrial epoxy multi-coat, anti-static ESD flooring with copper grounding network |
| Timeline | 12 weeks, phased to maintain partial operational continuity across the manufacturing programme |
This commission covered the principal floor systems of a pharmaceutical manufacturing facility within the Tema industrial corridor — a programme requiring the documented substrate engineering, regulatory compliance, and multi-stage QC discipline that pharmaceutical commissions invariably demand.
Specification Challenge
Pharmaceutical manufacturing commissions impose a regulatory standard that conventional industrial flooring rarely confronts: the floor must satisfy GMP hygiene requirements, support ISO 14644 cleanroom-adjacency airflow conditions, deliver documented IEC 61340-5-1 surface resistance compliance in ESD-controlled assembly zones, and resist the chemical exposure profile of pharmaceutical cleaning regimes — all while supporting the high-frequency wash-down and disinfection cycles that pharmaceutical operations execute daily.
The substrate presented the primary technical demand. Sub-floor moisture readings across the production halls were materially above safe thresholds for direct epoxy bonding, identified through ASTM F2170 in-situ probe testing conducted at the survey stage. Proceeding without remediation would have compromised bond integrity within twelve months — an outcome no GMP-regulated facility would accept. Substrate flatness, additionally, was outside the F-number tolerance required for the ESD grounding network to maintain continuity across the assembly-zone field.
Approach
The Floors GH project office structured the engagement in four documented phases, each with multi-stage QC sign-off before progression.
Phase 1 — Substrate Remediation. Following ASTM F2170 moisture mapping, affected zones received a moisture-suppression barrier system rated to the project’s GMP performance requirement. Substrate surface profiles were brought to ICRI CSP grade through diamond grinding before bonding-layer application.
Phase 2 — Self-Levelling Compound Underlay. Specification-grade self-levelling compound was pumped across the assembly-zone field, achieving the FF50 tolerance required for ESD grounding network continuity. Achieved F-numbers were measured and documented before any conductive coating was applied.
Phase 3 — Industrial Epoxy Multi-Coat. Across the production halls, a chemically-resistant epoxy system — primer, reinforced mid-coat, and chemical-resistant topcoat — was applied in controlled intervals with bubble-eliminating roller technique. Wash-down channels and equipment plinths were detailed to specification.
Phase 4 — ESD Flooring with Grounding Network. Across the assembly zones, a copper grounding network was installed and bonded to building-earth, conductive primer was applied to embed the network electrically, and a static-dissipative top layer was applied per IEC 61340-5-1 specification. Surface resistance and ground-strap continuity were measured at the specified grid density.
Outcome
- ASTM F2170 substrate moisture readings within specification tolerance across all zones at handover
- FF50 floor flatness compliance documented across the ESD assembly zone
- IEC 61340-5-1 surface resistance compliance verified at the specified grid density across the conductive flooring field
- Ground-strap continuity confirmed at every grounding point per commissioning protocol
- Written guarantee issued covering installation integrity across the full 2,400 sqm programme
- Zero pharmaceutical-operations downtime attributable to flooring works across the phased programme
What This Project Demonstrates
Pharmaceutical manufacturing in the Tema industrial corridor represents one of the most demanding intersections in Ghana’s specification flooring market: GMP regulatory exposure applied to a multi-system commission requiring substrate engineering, ESD compliance, and chemical-resistance integrity simultaneously, with no margin for operational interruption.
Floors GH has operated in this register since the practice was established 1972. The combination of ASTM F2170 moisture discipline, ICRI CSP substrate verification, IEC 61340-5-1 ESD compliance, and ASTM E1155 F-number documentation is not an elevated service tier — it is the baseline from which every project in the Tier-1 industrial and pharmaceutical sector is delivered. Where Ghana’s premier institutions step, the floor beneath them has been placed with this level of care.
Outcome with Measured Impact
The completed installation delivered 2,400 m² of pharmaceutical-grade epoxy across production zones, packaging, and adjacent material-handling corridors. ISO 14644-1 cleanroom classification verified at handover with subsequent re-verification at 12 and 24 months — both passing. FDA Ghana audit at month 18 returned zero non-conformance findings on flooring documentation. Production-floor downtime during install limited to 18 hours per zone via MMA cure cycle for the production-critical sections.
The facility’s regulatory affairs director confirmed in post-audit interview: floor documentation pack (substrate moisture verification per ASTM F2170, coating-system datasheets, batch records, install environmental conditions, post-install verification reports) satisfied audit requirements without supplementary documentation requests.
Why This Project Was Specified to Floors GH
The pharmaceutical client’s facility director had previously experienced a regulatory-audit non-conformance event traceable to inadequate flooring documentation at a different facility. The 2024 brief explicitly required documentation discipline integrated with FDA Ghana audit framework. Floors GH was selected for documented experience in pharmaceutical-grade installs, integration with the facility’s quality management system, and the project-office model providing single-point accountability across the install programme.
Related Reference Projects
Pharmaceutical and food-and-beverage industrial coating reference projects available for site visit on request, coordinated through each facility’s regulatory affairs director.