Stonchem 691 Conductive Novalac Epoxy Flooring Meets Critical ESD and Chemical Resistance Requirements for Pharmaceutical Facility

Project Overview

A leading pharmaceutical facility faced flooring failures across its 180,000 sq. ft. facility, including 30,000 sq. ft. of lab environments. The facility’s existing flooring system had broken down, which led to frequent repairs and increased maintenance costs. To address these issues, the facility sought a new, high-performance flooring solution that would deliver long-term durability, chemical resistance, and ESD performance.

Challenges & Requirements

The facility’s existing flake flooring system had deteriorated due to improper surface preparation and repeated layering over time. With an estimated five layers of coating over a mortar base, the floor was prone to failure, requiring constant repairs during scheduled shutdowns. This ongoing maintenance disrupted operations and increased costs. The environment demanded a seamless, exceptionally durable flooring system capable of withstanding a constant high volume of equipment traffic, exposure to harsh chemicals, and strict ESD-conductive requirements.

Stonchem 691 provides seamless ESD protection, exceptional chemical resistance, and long-term durability.

A failing floor transformed into a seamless, conductive Stonchem 691 system.

Solution

The project began with the complete removal of the existing flooring system using chipping hammers to ensure a clean substrate for proper adhesion. A 1/4-inch troweled layer of Stonclad GS epoxy mortar was applied to establish a robust, impact-resistant foundation. To address the facility’s ESD and chemical resistance requirements, two coats of Stonchem 691 – a fully conductive, novolac epoxy that incorporates cutting-edge carbon nanotube technology – were applied with an integrated conductive texture. This conductive aggregate was broadcast into the flooring system, backrolled, and the process repeated to ensure consistent coverage and dependable performance.

This durable, high-performance flooring system, formulated and installed to withstand the rigors of pharmaceutical environments, delivers easy cleaning and maintenance, regulatory compliance and operational safety, and long-term reliability and value for the customer.

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