Merck Animal Health achieves significant long-term savings with RIO Flooring’s Level 4 cleanroom flooring solution that reduces the need for repairs, maintenance and replacement.
About Merck Animal Health
Merck Animal Health is a leading pharmaceutical company specializing in animal medicine. The company uses the power of leading-edge science to save and improve lives around the world. For more than a century, Merck Animal Health has been at the forefront of research, introducing medicines, vaccines and innovative health solutions for the world’s most challenging diseases.
Situation
Merck Animal Health was expanding its operations with a new one-million-square-foot facility in De Soto, Kansas. The facility was dedicated to the manufacturing of vaccines and other high-value animal health products, requiring stringent cleanliness and durability standards.
The new facility demanded high-performance flooring and wall solutions that could meet the rigorous requirements of a Level 4 cleanroom environment. The primary concerns were ensuring that the surfaces were seamless, sterile, and resistant to both chemical and physical wear.
Merck Animal Health needed a solution that would provide long-term durability, minimize maintenance, and support the stringent cleanliness standards required for pharmaceutical manufacturing. Traditional options like Italian tile and Fiberglass Reinforced Plastic board presented challenges, such as grout lines and the risk of water penetration, which were unsuitable for the cleanroom environment.
Cleanroom Flooring Solution
Merck Animal Health selected RIO Flooring Systems to provide a comprehensive flooring and wall coating solution for the new facility. Leveraging our experience and close collaboration with the project’s architects and general contractors from the early stages, RIO Flooring delivered a tailored solution that exceeded Merck Animal Health’s expectations.
The scope of work included:
Consultative approach: RIO’s team provided consultative guidance throughout the project, advising on the appropriate vapor barrier beneath the concrete and working closely with the general contractor and architects to ensure that the installation met all specifications and standards.
High-performance urethane flooring: RIO installed a urethane cement floor with a full broadcast of sand, topped with a heavy coat of high-solids urethane, which is known for its superior abrasion and chemical resistance. This topcoat is four times more durable than traditional epoxy coatings, ensuring longevity and consistent performance.
Seamless wall and ceiling coatings: To further enhance the cleanroom's integrity, RIO extended the urethane coating system to the walls and ceilings, creating a completely seamless environment that is easy to clean and maintain. This solution prevents water ingress and ensures that no bacteria or contaminants can settle in cracks or crevices.
Results
The project resulted in a state-of-the-art, fully integrated cleanroom environment that met all of Merck Animal Health’s stringent requirements. The seamless urethane floor and wall system that RIO installed ensured a sterile manufacturing space, and also delivered significant durability and ease of maintenance.
The key benefits realized by Merck Animal Health include:
Enhanced durability: The high-solids urethane topcoat provides long-lasting protection against chemical and physical wear, ensuring that the flooring performs well under the demanding conditions of pharmaceutical manufacturing.
Seamless cleanability: The integrated floor, wall, and ceiling coatings create a smooth, seamless surface that is easy to clean, reducing the risk of contamination and supporting the facility’s high cleanroom standards.
Long-term cost efficiency: Despite the higher initial cost, the durability and performance of the urethane system offer significant long-term savings by reducing the need for repairs, maintenance and replacements.
Merck Animal Health expressed satisfaction with the quality and performance of the installation, recognizing RIO Flooring’s expertise and the value of our consultative approach. The project not only met but exceeded the client’s expectations, laying the groundwork for future collaborations on other high-profile projects.