EPOXY FLOORING SYSTEM FOR – ESD-CONTROLLED CLEANROOM ENVIRONMENTS

Introduction

Cleanroom environments demand extremely precise electrostatic discharge (ESD) control to protect sensitive equipment, maintain contamination-free conditions, and ensure uninterrupted performance of precision operations. Even a minor electrostatic imbalance can result in component failure, data corruption, or product rejection.

The Epoxy Flooring System for ESD-Controlled Cleanroom Environments by Ressichem provides a highly conductive, seamless, and durable epoxy floor system specifically engineered for cleanroom-grade environments. It ensures controlled and uniform static dissipation, in coordination with grounding networks, while maintaining a smooth, hygienic, and low-particle-emitting surface.

Recommended Use Cases

• Semiconductor and microchip manufacturing
• Pharmaceutical cleanrooms
• Medical device production facilities
• Precision laboratories and calibration zones
• Aerospace and defense electronics assembly
• Research & development centers with controlled ESD

Step-Wise System Description

Step 1: Surface Preparation

Proper substrate evaluation and preparation are critical to ensure uniform grounding and long-term ESD performance.

• All necessary surface repairs, including crack filling or substrate restoration, must be completed prior to the application of any epoxy flooring materials.
• The concrete strength requirement must be defined by the project consultant as per the operational load profile.
• Perform both destructive (core sample) and non-destructive Schmidt Hammer strength testing to verify substrate integrity.
• For major repairs ≥ 12 mm, apply Ressi NSG 710, a high-strength, non-shrink cementitious repair mortar.
• For minor imperfections, use Ressi EPO Primer LV blended with Ressichem’s washed, graded, and completely dried silica sand to form a moisture-free repair paste.
• Mechanically prepare the substrate through shot blasting or diamond grinding to ensure an oil-free, dust-free surface.
• In previously used floors, ensure full removal of oil or grease contamination before application.

Step 2: Application of Ressi SLS Primer – 1 and Ressi SLS 610 (If Required)

• If leveling is required to achieve a uniform substrate before epoxy application, apply Ressi SLS Primer – 1 followed by Ressi SLS 610, a self-leveling cementitious floor screed.
• Allow 7–14 days for the screed to release moisture depending on ambient temperature and humidity before proceeding with epoxy installation.
• Ensure moisture level < 5% before further coating.

Step 3: Application of Ressi EPO Primer LV and Copper Strip Installation

• Apply Ressi EPO Primer LV, a low-viscosity, solvent-free epoxy primer that promotes bonding and surface sealing.
• During this stage, the copper grounding network is integrated into the flooring system.
• Copper strips are bonded using Ressi EPO Primer LV over the prepared surface.
• The spacing, width, and thickness of the copper strips are to be determined according to the client’s ESD requirement.
• Once installed, the continuity and discharge capacity of the grounding system should be tested and verified before applying the conductive topcoat.
• This ensures that the entire copper grid forms a consistent and functional discharge path across the floor area.

Step 4: Application of Ressi EPO Anti-Static

• Apply Ressi EPO Anti-Static, a conductive epoxy topcoat that ensures seamless conductivity across the surface and effective connection to the copper grounding system.
• Apply the material at a minimum thickness of 1000 microns above the height of the copper strip layout.
• For example: if the copper strip thickness is 1000 microns, the total topcoat thickness should be 2000 microns.
• Apply using a notched trowel or epoxy squeegee, followed by back rolling to achieve a uniform finish.
• Allow the coating to fully cure before conducting ESD validation.

Step 5: Floor Markings (If Required)

• For cleanroom demarcations, apply Ressi EPO Anti-Static in a contrasting color using a roller at a thin coat thickness.
• This ensures that the visual layout complements the conductive flooring while maintaining its electrical continuity.

System Advantages

• Seamless ESD Control: Maintains consistent conductivity across the entire cleanroom floor area.
• High Cleanroom Compatibility: Smooth, dust-free, and low-particulate surface.
• Chemical Resistance: Withstands common cleaning and sterilization agents.
• Durability: Designed for heavy-duty cleanroom equipment and wheeled traffic.
• Hygienic Surface: Non-porous and easy to clean, maintaining GMP compliance.
• Grounded Safety: Provides reliable discharge pathways via copper strip integration.
• Customizable Finish: Available in cleanroom-appropriate colors and gloss levels.

Maintenance Guidelines

• Use only neutral pH cleaners to maintain coating integrity and conductivity.
• Avoid applying insulating waxes or sealers over the ESD surface.
• Inspect grounding points periodically for continuity.
• Periodic re-coating may be required to restore finish and maintain ESD consistency.
• Keep the cleanroom climate controlled to ensure consistent ESD performance.

System Summary Table

Parameter	Description
System Name	Epoxy Flooring System for – ESD-Controlled Cleanroom Environments
Area Type	Specialized / High-Performance – Cleanroom & ESD-Controlled Facilities
Traffic Exposure	Light to Heavy (as per cleanroom equipment)
Primary Requirements	Controlled ESD Discharge and Grounding Integration
Primer (Optional)	Ressi SLS Primer – 1 (for SLS systems)
Leveling Layer (Compulsory)	Ressi SLS 610 (if required)
Epoxy Primer	Ressi EPO Primer LV (used for both priming and copper bonding)
Conductive Layer	Ressi EPO Anti-Static (≥ 1000 microns above copper layout)
Silica Used	Washed, graded, and completely dried (zero moisture content) silica sand
Copper Grid Network	Installed and grounded as per site-specific ESD requirements
Application Method	High-Build Trowel or Epoxy Squeegee
Finish Type	Smooth, Low-Gloss / Semi-Gloss Conductive Finish
Curing Time Before Use	48–72 Hours (Light Access) / 7 Days (Full Cure)
Key Benefits	ESD Control, Durability, GMP Hygiene, Grounding Integration

Conclusion

The Epoxy Flooring System for ESD-Controlled Cleanroom Environments by Ressichem is a precision-engineered conductive epoxy system that integrates copper grounding with anti-static technology for complete electrostatic discharge management.

The combination of Ressi EPO Primer LV, embedded copper grid, and Ressi EPO Anti-Static creates a robust, hygienic, and reliable flooring solution tailored for pharmaceutical, semiconductor, and medical cleanroom environments.