Frequently Asked Questions

A pharmaceutical formulation plant in Noida is planning a new production block with a 2,000 square metre floor area requiring a hygienic, chemical-resistant floor system that meets WHO and GMP (Good Manufacturing Practice) requirements, can withstand caustic soda (2 percent NaOH) cleaning and occasional spills of isopropyl alcohol (IPA) and dilute hydrochloric acid, and provides a non-slip surface for the production staff — how should the flooring system be specified and what is the MC-Nafufill EM application methodology?

Specifying and installing a pharmaceutical GMP-compliant flooring system in a 2,000 square metre Noida production block is a project requiring careful integration of regulatory requirements, chemical compatibility, hygienic design, and construction quality. Here is the complete specification and application methodology for an MC-Nafufill EM-based flooring system. Regulatory and GMP flooring requirements: WHO GMP guidelines and Schedule M of the Drugs and Cosmetics Act (applicable to Indian pharmaceutical manufacturers) require production area floors to be smooth, impermeable, non-shedding, non-reactive with cleaning agents and spilled chemicals, seamless or with minimal sealed joints, and sloped to drains to prevent pooling. The floor must also be capable of withstanding cleaning and disinfection with 2 percent NaOH (caustic soda) solution, which is standard in pharmaceutical facility cleaning protocols (some facilities use up to 4 percent NaOH). Chemical compatibility check: MC-Nafufill EM epoxy mortar has confirmed chemical resistance to 2 percent NaOH (good), isopropyl alcohol (good — IPA does not attack cured epoxy at ambient temperature), and dilute hydrochloric acid up to 10 percent concentration (good) per the MC-Bauchemie chemical resistance table — confirm resistance for specific chemicals in your process against the full chemical resistance table in the Technical Data Sheet before specification. Substrate preparation: the concrete substrate must achieve a minimum 28-day compressive strength of M25 before applying the epoxy mortar system. Prepare the surface by shot-blasting (preferred) or diamond grinding to an ICRI Concrete Surface Profile (CSP) of 3 to 4, removing all laitance, contamination, curing compound, and existing coating from the entire floor area. Shot-blasting opens the surface pores, increases mechanical key for the epoxy primer, and removes weak surface layers that would cause delamination of the finished floor system. After shot-blasting, clean by vacuum and compressed air blow-off to remove all abrasive media and dust. Check moisture content of the concrete substrate using a CM moisture meter — the substrate must be below 4 percent MC (surface-dry condition) before applying epoxy primer. Primer application: apply MC-Pox 1K (single-component epoxy primer from MC-Bauchemie) or equivalent two-component epoxy primer at 0.15 to 0.20 kg per square metre by roller onto the prepared concrete, ensuring complete and uniform coverage over the entire 2,000 square metre floor. The primer penetrates the concrete pores and provides a chemically bonded interface between the concrete substrate and the subsequent epoxy mortar layer. Allow the primer to cure to tack-free (typically 4 to 8 hours at 25 degrees Celsius) before applying the epoxy mortar. MC-Nafufill EM screed application: mix Part A (epoxy resin) and Part B (hardener) in the specified ratio by mechanical stirrer for 3 minutes until homogeneous, then add the Part C aggregate gradually while continuing to mix for a further 2 to 3 minutes until the aggregate is evenly wetted and the mortar is smooth and lump-free. Do not add more aggregate than specified — excess aggregate reduces chemical resistance of the mortar matrix. For a pharmaceutical production floor, specify 20 mm mortar thickness (providing a robust, impact-resistant screed with a chemical reservoir depth sufficient to resist prolonged chemical contact). Apply the mixed mortar to the primed floor surface by gauged trowel and screed rails, working in bays of approximately 25 to 30 square metres that can be completed within the pot life (30 to 45 minutes at 25 degrees Celsius Noida conditions — plan smaller bays in summer when pot life shortens). Compact the mortar by cross-trowelling and roller tamping to eliminate air voids, then trowel to a smooth, level surface using a steel float. For a pharmaceutical floor, the surface finish should be smooth-trowelled (not broadcast-aggregate coated, which is used for anti-slip in general industry but is difficult to clean hygienically in pharma) — the anti-slip requirement is instead met by specifying a surface profile of R10 or R11 (per DIN 51130) achieved by fine-textured trowelling rather than aggregate broadcast. Joints: epoxy mortar is placed seamlessly within each bay; between bays, maintain a 5 mm expansion gap filled with a polyurethane or epoxy joint sealant (MC-Seal 180 or equivalent). At the wall-floor junction, form a 25 mm radius epoxy cove fillet (using epoxy mortar) in lieu of a sharp 90-degree angle — this is a GMP requirement for hygienic design, eliminating the dirt-trap at the wall-floor junction and facilitating cleaning. Drainage slope: before applying the epoxy mortar, verify the concrete substrate slope to all floor drains is minimum 1 in 100 (1 percent slope) — if the substrate is flat, the epoxy mortar layer can be used to form the drainage slope by applying it at varying thickness (minimum 10 mm at the high point, increasing to 25 to 30 mm at the drain). Drains themselves should be stainless steel (SS 316L grade for pharmaceutical GMP) with hygienic grating designs. Curing and commissioning: cure the applied MC-Nafufill EM screed at ambient temperature for minimum 7 days before exposing to chemical cleaning or spill contact — during the first 7 days, epoxy continues to cross-link and develop full chemical resistance. Do not expose the floor to NaOH cleaning or IPA contact before 7 days minimum. After 7 days curing, test bond strength by pull-off (minimum 3 random locations per 200 square metres) before commissioning the floor. The target pull-off strength for the GMP flooring specification is minimum 2.5 MPa — a result of 3.0 MPa or above (concrete failure) confirms complete bonding. Space Arc Engineering supplies MC-Nafufill EM, MC-Pox 1K primer, and MC-Seal 180 joint sealant for pharmaceutical and industrial flooring projects in Noida, Ghaziabad, Delhi NCR, and Uttar Pradesh, and provides on-site technical supervision for flooring system installation in GMP-regulated environments.