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High Performance Interior Wall Systems

All surfaces require finishing to meet the needs of the facility. In most household and office environments this treatment is primary decorative in nature. Institutional facilities and "clean" manufacturing facilities on the other hand must have wall surfaces that are made to withstand wash down conditions and occasional impacts. Typically, food and beverage processing facilities, schools, detention facilities, electronics manufacturing and pharmaceutical production areas require high-build durable polymeric finishes. Epoxy wall systems have served this application throughout the years and continue to be the system of choice when specifying these applications. General Polymers has recently upgraded these systems to include an optional light stable durable 100% solids chemical resistant urethane topcoat, POLYCOTE™(4685W). Three polymeric wall systems are available: SANIGLAZE™, SANIGLASS™;, and SANIFLEX™.

Block Walls

Block or concrete walls are porous and will absorb moisture and other liquids. Given the right environment an unsealed concrete or block wall will harbor microorganisms which may affect the health of the employees and the quality of products being produced. In most cases, block walls present a highly porous texture which is difficult to seal with a simple epoxy wall coating. In these situations General Polymers recommends the use of a Block Filler (2400) prior to the application of the wall system. SANIFLEX™ is the preferred wall system over block or concrete walls. The system is built with two coats (10-15 mils each) of EPO-FLEX™ Wall Coating and a topcoat of POLYCOTE™ Wall Coating (4685W). This system provides crack bridging, chemical resistance and impact resistance while maintaining a UV stable high gloss stipple finish. Another option, SANIGLAZE™, is a two coat, rigid epoxy system resulting in a high gloss, stipple finish.

Drywall

Dry wall or sheet rock provides a smooth uniform substrate at the expense of surface strength and impact resistance. This situation has traditionally required the use of a reinforced wall coating, such as Saniglass Wall System. In order to strengthen the wall, a fiberglass mat or cloth is embedded into a coating of high build epoxy. Subsequent coats of epoxy add strength and cover the fiberglass to provide a smooth, cleanable, stipple surface. All epoxies will discolor over time; therefore the final topcoat should be a light stable urethane (POLYCOTE™ 4685W). As an alternative, SANI-FLEX™ Wall System will provide a thermal shock resistant, non-porous and cleanable surface ideal for most pharmaceutical and clean room environments.

Cove Base

The wall to floor transition in a "clean" facility is a necessity. When a cove base is incorporated it is recommended that the cove be terminated at the top with a featheredge (Figure 2) and the wall system overlaps the top of the cove. This results in a "negative" edge which will not collect dirt and dust. In the case of block walls the cove base can be terminated into a mortar joint providing a sound bond and a flat finish for the wall system to cover.

Summary

Wall systems are extremely important to the overall environment of the facility. Epoxy and urethane high build systems provide a proven solution to the needs of maintaining a clean environment. Incorporation of EPO-FLEX™ as a high build, flexible epoxy base with a light stable, chemical resistant urethane provides a better solution for most sanitary wall applications. All of General Polymers wall systems are available with an antimicrobial additive, which will help to maintain a low bioburden between cleanings.