In pharmaceutical facilities, flooring is more than just a surface to walk on—it’s an essential part of maintaining compliance, safety, and product integrity. Even small cracks in a floor can compromise sanitation, harbor bacteria, and risk regulatory violations. For leaders in the pharmaceutical industry, ensuring that floors remain durable and defect-free is a critical priority.
At CustomCrete, we’ve worked with pharmaceutical facilities across Chicago and the Midwest, providing solutions that prevent floor failure while supporting strict industry standards. In this blog, we’ll explore how to prevent concrete from cracking, what causes damage in pharmaceutical floors, and the best practices for long-term performance.
Why Cracks in Pharma Facility Floors Are a Serious Risk
Unlike general commercial environments, pharmaceutical floors must meet strict Good Manufacturing Practices (GMP) and regulatory requirements. Cracks or damage aren’t just cosmetic—they can:
- Create spaces for dust, dirt, and microbes to collect, making sanitation more difficult.
- Compromise cleanroom conditions, threatening compliance with FDA and USDA standards.
- Reduce chemical resistance, leading to surface breakdown when exposed to disinfectants or solvents.
- Increase safety risks for staff and equipment, especially with wheeled carts and forklifts.
Left unaddressed, even minor floor cracks can escalate into costly repairs and operational downtime.
Common Causes of Cracks and Damage
Understanding how to prevent concrete from cracking starts with knowing why it happens. In pharmaceutical environments, the most common causes include:
- Moisture movement: Excessive vapor transmission can weaken coatings and cause delamination.
- Thermal shock: Floors exposed to hot water washdowns or chemical cleaning cycles can expand and contract, creating stress cracks.
- Heavy loads: Equipment, pallet jacks, and carts add stress to the surface and joints.
- Improper prep or coatings: Floors not designed for chemical resistance may fail prematurely under pharma-grade cleaners and sanitizers.
Design and Installation Best Practices
The best way to prevent cracks is to design a flooring system with pharmaceutical operations in mind from the start. This includes:
- Proper concrete prep: Shotblasting or grinding creates the right surface profile for coatings to bond effectively.
- Moisture testing: Using RH probes or calcium chloride tests ensures the slab is ready for coatings.
- High-performance coatings: Epoxy and urethane cement are popular choices for pharmaceutical floors because they provide seamless, chemical-resistant surfaces.
- Cove base installation: Extending flooring up the walls eliminates vulnerable floor-to-wall joints where cracks often form.
These proactive steps create a flooring foundation that is built for the rigorous demands of pharmaceutical production.
Maintenance Strategies for Longevity
Once installed, ongoing maintenance is key to preventing cracks and damage. Pharmaceutical facilities should:
- Schedule regular inspections to catch early signs of wear, joint separation, or coating damage.
- Use low-pH cleaners that are effective without being overly harsh on coatings.
- Repair small issues quickly before they spread into larger cracks.
- Reapply sealers or topcoats on a set schedule to maintain chemical and moisture resistance.
By making maintenance part of daily facility management, companies can protect both their floors and their compliance status.
Repair vs. Replacement: Knowing When It’s Time
Even with preventive measures, damage can sometimes occur. The decision to repair or replace comes down to the severity of the cracks:
- Minor cracks and surface wear: Often repaired with patching materials or localized coating.
- Significant joint damage or delamination: May require partial resurfacing.
- Widespread cracking or contamination risk: Full replacement with a new high-performance system may be the best option.
Working with an experienced contractor helps facility managers make the right call while minimizing downtime.
Conclusion: Building Strong Floors for Pharma Environments
For pharmaceutical facilities, protecting floors from cracks and damage is about much more than aesthetics—it’s about compliance, sanitation, and safety. By investing in proper prep, high-performance coatings, and ongoing maintenance, you can minimize risks and extend the life of your flooring system.
At CustomCrete, we bring decades of experience designing flooring systems that hold up under the strict demands of the pharmaceutical industry. Our team understands the balance between durability, compliance, and efficiency, ensuring floors that perform today and for years to come.
Next Read: Learn more about pharmaceutical flooring options in our blog, “Why Epoxy and Urethane Cement Are Ideal for Pharmaceutical Manufacturing Floors”.
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