Pharmaceutical & Biotechnology Flooring Systems
Pharmaceutical production plants, API manufacturing, biologics and cell therapy suites, vaccine production, medical device plants, research laboratories, vivariums. One campus, a dozen floor conditions. Maverick engineers a different build for each zone — coved, seamless, cleanable — and installs it with our own crews, phased around running operations.
Pharmaceutical, Biotech & Medical Device Facilities
From API synthesis to sterile packaging, the floor conditions change with every door. These are the facility types this page addresses; the vivarium and cleanroom & laboratory guides go deeper on those zones.
- Pharmaceutical production plants
- Active pharmaceutical ingredient (API) manufacturing
- Sterile pharmaceutical manufacturing
- Injectable drug manufacturing
- Vaccine production
- Biopharmaceutical manufacturing
- Cell therapy manufacturing
- Biologics production
- Fermentation facilities
- Pharmaceutical packaging
- Medical device manufacturing
- Research and development laboratories
- Biosafety laboratories
- Vivariums
One Campus, Many Floors
A pharmaceutical or biotech plant is not one application. The API suite lives under solvents and concentrated acids. The fill-finish suite lives under daily sporicidal sanitation. The gowning corridor takes carts and foot traffic all shift and has to stay low-particulate. The warehouse takes forklifts. The CIP room takes hot caustic and acid cycles. The vivarium takes cagewash steam. Each zone gets its own build.
Across all of them the floor is coved, seamless, and cleanable — built to support the facility’s validation and sanitation programs rather than fight them. Containment is detailed to the stored chemistry and the inspection regime. Classified cleanrooms and aseptic suites get the same seamless, coved, low-particulate build, static-dissipative where the ESD program calls for it.
API / Chemical Synthesis & Solvent Handling
Solvents, concentrated acids, caustics, and drum traffic. ¼″ troweled epoxy mortar with a novolac topcoat where the chemistry is aggressive, containment curbs and trenches detailed at the corners.
Production & Fill-Finish Suites
Daily sanitation chemistry, cart traffic, and washdown. Urethane cement where hot water and thermal cycling are in play; seamless epoxy with integral cove base on dry-side suites. Built for the sanitation program to clean and document.
Cleanroom Support Corridors & Gowning
Foot and cart traffic all shift, frequent disinfection, low-particulate requirement. Seamless epoxy coatings with integral cove and color demarcation at the transitions. Our cleanroom & laboratory guide covers the classified core.
Warehouse & Packaging
Forklifts, pallet jacks, abrasion, and joint shoulders that break down under wheels. A coating built for traffic, with joints honored through the new floor.
Utility / Mechanical & CIP Chemical Rooms
Hot caustic and acid CIP cycles, steam, condensation, and spills from chemical totes. Thermal-shock-rated urethane cement with a chemical-resistant topcoat and curbed containment.
Vivarium & Research Labs
Daily washdown and sanitizers in holding rooms, live steam in cagewash, reagents at the bench. Broadcast systems with integral cove in holding rooms and labs; urethane cement in cagewash. See the vivarium guide.
| Zone | Primary Exposure | Typical Starting Point | Nominal Thickness |
|---|---|---|---|
| API / Chemical Synthesis & Solvent Handling | Solvents, concentrated acids, caustics; drum and tote traffic; spill containment | MavClad EM epoxy mortar with MavCoat NV novolac topcoat; containment detailing | ¼″ |
| Production & Fill-Finish Suites | Sporicidal sanitation, cart traffic, washdown and thermal cycling | MavCrete UM urethane cement for hot washdown; MavClad EM or MavCoat CRE on dry-side suites; integral cove base | ¼″ |
| Cleanroom Support Corridors & Gowning | Foot and cart traffic; frequent disinfection; low-particulate requirement | Seamless MavCoat CRE / SLE epoxy coating with integral cove; color zoning at transitions | — |
| Warehouse & Packaging | Forklift and pallet-jack traffic; abrasion; joint movement | MavCoat HB / PC traffic coating; MavJoint JF at moving joints | — |
| Utility / Mechanical & CIP Chemical Rooms | Hot CIP caustic and acid cycles; steam; thermal shock; chemical spills | MavCrete UM with MavCoat NV chemical-resistant topcoat; curbed containment | ¼″ |
| Vivarium & Research Labs | Daily washdown and sanitizers; cagewash steam; bench reagents | MavTop quartz broadcast with integral cove in holding rooms and labs; MavCrete UM in cagewash | ¼″ |
Starting points, not prescriptions. Every Maverick system is engineered to the condition of the substrate, the abuse it takes, and the facility’s history with previous floors — the build changes from room to room and plant to plant. Only new construction over bare concrete comes close to a standard build.
The Systems This Work Demands
MavClad EM Epoxy Mortar
¼″ troweled, chemically resistant — the heavy-duty body under API, synthesis, and solvent-handling floors, with integral cove base.
Explore the SystemMavCrete UM Urethane Cement
Thermal-shock-rated mortar for hot washdown, CIP chemical rooms, cagewash, and production suites that sanitize hard.
Explore the SystemMavCoat CRE & NV Coatings
Chemical-resistant and novolac epoxy coatings — the seamless, cleanable finish over the mortar body, or the floor itself on light-duty suites and corridors.
Explore the SystemBuilt in Our Own Plants, Installed by Our Own Crews
Maverick formulates and batches its products in our own plants, installs with our own crews, and backs the floor with a single-source warranty and a 48-hour response. Every build is engineered to the sanitation chemistry, the containment requirement, and the slab — not pulled from a price sheet. Below: a seamless broadcast floor detailed tight to a stainless process-vessel base, the equipment-base condition that production, fermentation, and CIP rooms present.
Broadcast floor at a stainless vessel base — seamless, textured, detailed to the equipment
Specify It Once, Correctly
The Architect Center carries the full standard detail library, isometric system shop drawings, and CSI 3-part specifications under Section 09 67 23 Resinous Flooring — including integral cove base and coved, seamless transition details for sanitized suites.
Pharmaceutical Flooring Questions, Answered Straight
Is there one floor system for a pharmaceutical plant?
No. The same campus needs different builds in different zones. API and solvent-handling areas start from ¼″ MavClad EM epoxy mortar, often with a MavCoat NV novolac topcoat. Production, fill-finish, and CIP rooms that take hot washdown start from MavCrete UM urethane cement. Gowning corridors and dry-side suites start from seamless MavCoat epoxy coatings. Warehouses take a coating built for forklift abrasion. Every build is then adjusted to the slab, the abuse, and the facility’s history with previous floors.
What makes a floor cleanable in a production or fill-finish suite?
No joints, no seams, and no sharp inside corners. Maverick installs the floor monolithically with an integral cove base so the floor-to-wall transition is one continuous, cleanable surface. The finish is selected for the sanitation chemistry in use, and the build is engineered to support the facility’s validation and sanitation programs. We build the floor the program can clean and document.
How do you handle solvents and concentrated acids in API areas?
With resin chemistry matched to the exposure. MavClad EM gives a chemical-resistant ¼″ mortar body; where concentrated acids are present, MavCoat NV novolac epoxy — which resists concentrated acids including 98% sulfuric acid — goes on as the topcoat. Containment curbs, trenches, and sumps are detailed at the corners and terminations where containment fails. Containment is specified to the documented chemistry and dwell time, not the room name — starting from the chemical-resistance chart on each product data sheet.
Can the work be phased around a running facility?
Yes. We phase suite by suite and corridor by corridor, with zero-VOC options such as MavCoat CRE and MavCoat NV where odor matters, and fast-cure options where the shutdown window is measured in hours. Tell us the shutdown window and the sequence of suites and we will engineer the build and the crew plan to fit inside it.
Working on the classified core or an animal facility? See the cleanroom & laboratory flooring guide and the vivarium flooring guide.
Planning This Work?
Shutdown windows, suite-by-suite phasing, sanitation chemistry, containment — bring us the constraint and we will engineer the floor around it.