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After being contracted by Boulting Environmental Services (BES), Kemtile were asked to install a high performance Stonhard flooring system at Astra Zeneca as part of the refurbishment of an existing warehouse into a state of the art pharma packaging facility at its global manufacturing site in Macclesfield, Cheshire.

The site is the company’s European centre for packing and distributing to 130 global markets. It’s also its second largest global manufacturing facility for medicines such as legacy prostate cancer drug Zoladex.

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Stonhard epoxy flooring

AstraZeneca is a longstanding customer of BES, the design-led construction experts who have provided multidisciplinary engineering services to AstraZeneca’s Macclesfield site for almost 20 years. On this particular contract, a resin flooring system capable of being installed in very large areas was required, and BES recommended Stonhard – the leading manufacturer of resin flooring, wall and lining systems – installed by Kemtile.

Kemtile installed a total of 6500m2 of high-performance Stonhard epoxy flooring systems throughout the new pharma production facility and cleanrooms.

Osmosis problem sorted

The flooring system design needed to take into account the possibility of problems with osmosis in the existing structural concrete so Stonhard’s, Stonfil OP2, an osmotic pressure-resistant grout was installed first before the final Stonhard finishes. Stongard MR was proposed for the plant rooms and workshop areas. This is a nominal 1mm thick elastomeric flooring system developed for positive side waterproofing applications - protecting areas below mechanical rooms, pump and mezzanine floors.

New Cleanroom floors

Stonhard’s Stontec ERF system was also recommended and installed in the new-build cleanrooms. This high performance decorative flake flooring epoxy-based system is dense, stain-resistant and available in an extensive range of finishes and colour options. Stontec ERF is a popular choice with design teams for pharma labs and is the perfect product for quick installations.

Working in partnership

Dave Greaves, Senior Construction Manager at BES, said: “This is the first project that we've undertaken with the Stonhard team and we were immediately impressed with their knowledge and experience, which was clear from the solution that they developed in response to our brief. “Add to this the product quality and reputation of Stonhard systems in pharma and healthcare facilities across the globe, and it made perfect sense for our client. They did an excellent job.”

Kemtile Technical Manager Steve Lyon said: “Stonhard's 90-years experience and knowhow gained in pharma and wider sectors – combined with Kemtile's 40-years of operation - underpinned the design and installation of this flooring project for AstraZeneca. “Our products have proven themselves time and time again over the years and we're delighted that our manufacturing and installation capabilities have now been recognised by such an important supplier to a global pharma player.”