A seamless impermeable construction process for clean floor of a pharmaceutical clean room

Abstract

This invention discloses a seamless anti-seepage construction process for cleanroom floors in pharmaceutical cleanrooms. In this invention, a chemical anchoring point is generated in situ at the interface between the self-developed alkali-resistant glass fiber mesh fabric and the alkaline component-triggered release mechanism of the outer microencapsulated active silica coating, forming a gradient transition structure from the fiber matrix to the coating. This effectively resists interfacial peeling and fatigue cracking under dynamic temperature differences and vibration environments. Through the alignment of the leveling layer grooves and the mesh fabric's air-guiding grooves, and a micro-negative pressure exhaust process, residual moisture in the bottom layer is forcibly extracted and the microencapsulated wall material is activated simultaneously. Then, the residual negative pressure difference actively draws the intermediate coating slurry into the bottom of the grooves and the tips of cracks, eliminating capillary leakage paths. Simultaneously, the topcoat and intermediate coating directly chemically cross-link during the gelation window, forming a continuous, seamless anti-seepage shell, significantly shortening the construction cycle and reducing the risk of cleanroom grade failure.

Description

Technical Field

[0001] This invention belongs to the field of pharmaceutical production technology, specifically a seamless anti-seepage construction process for cleanroom floors in pharmaceutical manufacturing. Background Technology

[0002] Pharmaceutical cleanrooms place extremely high demands on the sealing and impermeability of their flooring systems. The floor must withstand repeated erosion from powerful cleaning agents and humid steam during daily cleaning and disinfection operations, and maintain its integrity under dynamic loads such as equipment movement, temperature and humidity fluctuations, and micro-vibrations. Any cracks, bulges, or delamination can lead to the growth of particles and microorganisms in hidden areas, thus affecting the cleanliness level and the quality of pharmaceutical production. Seamless impermeable flooring construction in pharmaceutical cleanrooms refers to the technical process of constructing an industrial flooring system with integrity, density, and chemical resistance using high-performance resin materials and a specific multi-layer coating process. This construction technique typically uses epoxy resin or polyurethane as the main material, applying a primer, a mid-coat for leveling, and a topcoat for sealing on a rigorously treated base surface to form a seamless, continuous coating. Its core function is to eliminate gaps and pores in the floor, prevent dust accumulation and microbial growth, and effectively block the downward penetration of acidic and alkaline solvents and cleaning agents used in the production process. This seamless flooring system is not only easy to clean and disinfect, meeting the stringent GMP requirements for clean environments, but also a key foundational engineering project for ensuring aseptic control in pharmaceutical production environments, avoiding cross-contamination, and extending the service life of facilities. Currently, clean floors in pharmaceutical workshops generally use a multi-layer epoxy resin coating system. During construction, the primer is applied, mortar is leveled, mesh reinforcement is applied, intermediate coat is applied, and topcoat is poured. The layers rely on physical bonding after curing to form a whole.

[0003] However, in the existing technology, ordinary glass fiber mesh and epoxy resin system are only physically interlocked. In the frequent temperature changes and humid and hot environment of cleaning and disinfection in pharmaceutical workshops, it is easy to cause interfacial peeling and microcrack propagation. At the same time, interlayer treatment requires additional application of interface agent and increases waiting time, which greatly prolongs the construction cycle. Moreover, the risk of interlayer separation is high after long-term use. Summary of the Invention

[0004] The purpose of this invention is to provide a seamless anti-seepage construction process for cleanroom floors in pharmaceutical manufacturing facilities in order to solve the problems mentioned above.

[0005] The technical solution adopted in this invention is as follows: A seamless anti-seepage construction process for cleanroom floors in pharmaceutical manufacturing facilities, comprising the following steps: S1: Clean and repair the base layer, sand it to a solid surface, rinse and dry it, measure the moisture content and record it on the wall.

[0006] S2: Apply the penetrating primer by roller, mark the surface drying time, and scrape the leveling layer after surface drying.

[0007] S3: Apply epoxy mortar leveling layer to the design thickness. Before initial setting, use a notched trowel to create a shallow groove and measure the thickness.

[0008] S4: Lay alkali-resistant glass fiber mesh cloth. The cloth is based on high zirconium glass fiber, with an inner layer coated with nano-montmorillonite modified acrylic and an outer layer coated with an acrylic coating containing microencapsulated active silica by electrostatic gradient spraying. The microcapsule wall material is a polymer that is slow to dissolve in alkali.

[0009] Lay the mesh fabric flat on the grooved surface of the leveling layer, with the raised air-guiding grooves facing downwards and aligned with the groove. Overlap adjacent edges of the fabric by 50mm. Secure a closed annular air collection pipe along the perimeter of the entire mesh fabric using a pressure strip. Open air intakes every 300mm along the pipe, pointing downwards towards the end or intersection of the grooves below. Temporarily seal the gap between the air collection pipe and the ground with sealing tape. Connect the air collection pipe to the outdoor vacuum pump via a flexible hose.

[0010] Start the vacuum pump and maintain a negative pressure of -0.02 to -0.04 MPa until the next step of applying the intermediate coating slurry begins. This negative pressure not only continuously extracts residual moisture and air from the leveling layer, but also causes the microcapsule wall material to develop micro-cracks, putting it in a state of readiness for activation. At the same time, the negative pressure adsorption force tightly presses the mesh cloth against the bottom of the groove, ensuring that the air-guiding groove is not flattened, thus reserving a continuous channel for the rapid penetration of the subsequent slurry.

[0011] S5: Within 5 minutes after the vacuum is turned off, apply a high-solids epoxy intermediate coating. The alkaline nature of the slurry triggers the dissolution of the microcapsule wall material, releasing active silicon powder and chemically intercalating with the epoxy. At the same time, the negative pressure difference causes the slurry to be drawn into the groove and filled. After leveling, let it stand until it is no longer sticky to the touch.

[0012] S6: The gel window is filled with a self-flowing surface coating, and the defoaming roller breaks the bubbles, and the two layers are chemically cross-linked into a whole.

[0013] S7: After 48 hours of curing, wipe with a damp cloth to ensure no water seepage, polish, measure resistance, and hand over if qualified.

[0014] In a preferred embodiment, in step S1, the base layer is cleaned to remove the surface slurry, oil stains and loose layer, and then sanded with an angle grinder until a solid base surface is exposed. After rinsing with a high-pressure water gun, it is allowed to air dry until there are no obvious water marks on the surface. Cracks and depressions with a width of more than 0.2 mm are filled and smoothed with epoxy putty. Then, the flatness is checked with a 2m straightedge to ensure that the maximum gap is no more than 2 mm.

[0015] In a preferred embodiment, in step S2, a low-viscosity epoxy primer is mixed in a certain proportion and rolled onto the substrate surface in the same direction using a short-nap roller, with the coating amount controlled at 0.15–0.20 kg / m². 2 .

[0016] In a preferred embodiment, in step S3, while the primer is still partially dry, the epoxy mortar leveling material is poured onto the ground and continuously scraped with a notched scraper to a designed thickness of 3 to 5 mm, with an overlap of at least 100 mm between each scraping strip; immediately after scraping, while the mortar is still in its plastic pre-setting stage, shallow grooves are pulled vertically with a special notched trowel, the grooves being approximately 0.5 mm deep and spaced approximately 20 mm apart. The grooving operation must be completed before the mortar initially sets.

[0017] In a preferred embodiment, in step S4, the alkali-resistant glass fiber mesh fabric formulation includes: 60-70 parts by weight of silica, 8-10 parts by weight of calcium oxide, 5-8 parts by weight of magnesium oxide, 0-5 parts by weight of aluminum oxide, 0-3 parts by weight of titanium dioxide, 0.5-5 parts by weight of zirconium oxide, the balance of alkali metal oxides, 20-30 parts by weight of modified acrylic copolymer emulsion, 1-3 parts by weight of nano-montmorillonite, 0.2-0.5 parts by weight of titanate coupling agent, 0.2-0.5 parts by weight of zirconate coupling agent, 15-25 parts by weight of acrylic copolymer emulsion, and 5-10 parts by weight of microencapsulated active aggregate. The microencapsulated active aggregate consists of a core material and a wall material. The core material is ultrafine active silica or metakaolin powder, and the wall material is a polymer material that can be slowly dissolved in alkali.

[0018] In a preferred embodiment, in step S4, the mesh fabric is laid flat on the grooved surface of the leveling layer, with the raised grooves of the fabric facing downwards and aligned with the grooves. Adjacent fabric edges overlap by 50mm and are fixed with epoxy mortar. A closed annular gas collection pipe is fixed along the perimeter of the entire mesh fabric with a pressure strip. Air intakes are opened every 300mm downwards on the pipe body, with the air intakes facing the end of the groove below or the intersection of the grooves. The joint between the gas collection pipe and the ground is temporarily sealed with sealing tape to prevent air leakage. The gas collection pipe is connected to an outdoor vacuum pump through a flexible hose. The three data points marked on the wall are used to confirm whether the overall condition meets the laying conditions.

[0019] In a preferred embodiment, in step S4, after starting the vacuum pump, the negative pressure value is maintained at -0.02 to -0.04 MPa and is continuously maintained until the next step of applying the intermediate coating slurry begins.

[0020] In a preferred embodiment, in step S5, within 5 minutes after the vacuum pump is turned off, the high-solids epoxy intermediate coating slurry is poured onto the mesh cloth, and the first intermediate coating is applied with an elastic scraper to a thickness of about 2 mm. The alkaline components in the slurry contact the microcracks in the microcapsule wall material, causing it to slowly dissolve and release active silica to chemically intercalate with the epoxy. At the same time, the suction force of the previous negative pressure actively draws the slurry into the bottom of the groove and the tip of the crack, achieving filling without dead corners.

[0021] In a preferred embodiment, in step S6, during the gel window period of the intermediate coating, the self-leveling epoxy topcoat material is mixed according to the formula and stirred thoroughly to remove bubbles, and then poured evenly onto the surface of the intermediate coating. The thickness of the topcoat is controlled to be 1.0 to 1.5 mm using a trowel.

[0022] In a preferred embodiment, in step S7, the air conditioning system is turned off within 24 hours after the topcoat is applied, the ground is kept undisturbed, the ambient temperature is maintained at 20 to 25°C, and the relative humidity is below 75%. The temperature and humidity values ​​marked on the wall are checked and recorded every 8 hours. During the curing period, no items should be stepped on or piled up. After 48 hours of curing, wipe all areas of the surface with a cotton cloth moistened with clean water and observe whether there is any water seepage, discoloration or dampness to confirm that the impermeability is qualified.

[0023] In summary, due to the adoption of the above technical solution, the beneficial effects of the present invention are: 1. In this invention, through the release mechanism triggered by the alkaline components of the microencapsulated active silica coating on the outer layer of the self-developed alkali-resistant glass fiber mesh and the intermediate coating slurry, chemical anchoring points can be generated in situ at the interface between the mesh and the intermediate coating, forming a gradient transition structure from the fiber matrix to the coating, effectively resisting interface peeling and fatigue cracking under dynamic temperature difference and vibration environment.

[0024] 2. In this invention, by matching the leveling layer groove with the mesh cloth air-guiding groove and the micro-negative pressure exhaust process, the residual moisture in the bottom layer can be forcibly extracted and the microcapsule wall material can be activated simultaneously. Then, the residual negative pressure difference is used to actively draw the intermediate coating slurry into the bottom of the groove and the tip of the crack, eliminating the capillary leakage path. At the same time, the topcoat and intermediate coating directly chemically cross-link during the gelation window period to form a continuous seamless impermeable shell, which significantly shortens the construction cycle, reduces the risk of cleanliness level failure, and ensures that the long-term sealing and impermeability performance of the pharmaceutical workshop floor meets the standards. Attached Figure Description

[0025] Figure 1 This is a schematic diagram illustrating the process principle of the present invention; Figure 2 This is a schematic diagram comparing the mechanical properties and interfacial bonding strength in this invention; Figure 3 This is a schematic diagram comparing the impermeability and durability of the present invention; Figure 4 This is a schematic diagram comparing construction efficiency and overall cost in this invention. Detailed Implementation

[0026] To make the objectives, technical solutions, and advantages of this invention clearer, the invention will be further described in detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative and not intended to limit the invention.

[0027] Example: Reference Figure 1-4 A seamless anti-seepage construction process for cleanroom floors in pharmaceutical manufacturing includes the following steps: S1: Clean and repair the base layer, sand it to a solid surface, rinse and dry it, measure the moisture content and record it on the wall.

[0028] S2: Apply the penetrating primer by roller, mark the surface drying time, and scrape the leveling layer after surface drying.

[0029] S3: Apply epoxy mortar leveling layer to the design thickness. Before initial setting, use a notched trowel to create a shallow groove and measure the thickness.

[0030] S4: Lay alkali-resistant glass fiber mesh cloth. The cloth is based on high zirconium glass fiber, with an inner layer coated with nano-montmorillonite modified acrylic and an outer layer coated with an acrylic coating containing microencapsulated active silica by electrostatic gradient spraying. The microcapsule wall material is a polymer that is slow to dissolve in alkali.

[0031] Lay the mesh fabric flat on the grooved surface of the leveling layer, with the raised air-guiding grooves facing downwards and aligned with the groove. Overlap adjacent edges of the fabric by 50mm. Secure a closed annular air collection pipe along the perimeter of the entire mesh fabric using a pressure strip. Open air intakes every 300mm along the pipe, pointing downwards towards the end or intersection of the grooves below. Temporarily seal the gap between the air collection pipe and the ground with sealing tape. Connect the air collection pipe to the outdoor vacuum pump via a flexible hose.

[0032] Start the vacuum pump and maintain a negative pressure of -0.02 to -0.04 MPa until the next step of applying the intermediate coating slurry begins. This negative pressure not only continuously extracts residual moisture and air from the leveling layer, but also causes the microcapsule wall material to develop micro-cracks, putting it in a state of readiness for activation. At the same time, the negative pressure adsorption force tightly presses the mesh cloth against the bottom of the groove, ensuring that the air-guiding groove is not flattened, thus reserving a continuous channel for the rapid penetration of the subsequent slurry.

[0033] S5: Within 5 minutes after the vacuum is turned off, apply a high-solids epoxy intermediate coating. The alkaline nature of the slurry triggers the dissolution of the microcapsule wall material, releasing active silicon powder and chemically intercalating with the epoxy. At the same time, the negative pressure difference causes the slurry to be drawn into the groove and filled. After leveling, let it stand until it is no longer sticky to the touch.

[0034] S6: The gel window is filled with a self-flowing surface coating, and the defoaming roller breaks the bubbles, and the two layers are chemically cross-linked into a whole.

[0035] S7: After 48 hours of curing, wipe with a damp cloth to ensure no water seepage, polish, measure resistance, and hand over if qualified.

[0036] In step S1, clean the base layer to remove laitance, oil stains, and loose layers from the ground. Grind with an angle grinder until a solid base surface is exposed. Rinse with a high-pressure water gun and allow to air dry until there are no obvious water marks on the surface. Fill and smooth any cracks or depressions wider than 0.2mm with epoxy putty. Then check the flatness with a 2m straightedge to ensure that the maximum gap is no more than 2mm.

[0037] In step S2, low-viscosity epoxy primer is mixed in a certain proportion and applied to the substrate surface using a short-nap roller in the same direction. The coating amount is controlled at 0.15–0.20 kg / m². 2 .

[0038] In step S3, while the primer is still partially dry, pour the epoxy mortar leveling material onto the ground and continuously scrape it with a notched trowel to the designed thickness of 3 to 5 mm, ensuring an overlap of at least 100 mm between each scraping strip. Immediately after scraping, while the mortar is still plastic and not yet fully set, use a special notched trowel to create shallow grooves vertically. The grooves should be approximately 0.5 mm deep and spaced about 20 mm apart. This grooving work must be completed before the mortar begins to set.

[0039] In step S4, the alkali-resistant glass fiber mesh fabric formulation includes: 60-70 parts by weight of silica, 8-10 parts by weight of calcium oxide, 5-8 parts by weight of magnesium oxide, 0-5 parts by weight of aluminum oxide, 0-3 parts by weight of titanium dioxide, 0.5-5 parts by weight of zirconium oxide, the balance of alkali metal oxides, 20-30 parts by weight of modified acrylic copolymer emulsion, 1-3 parts by weight of nano-montmorillonite, 0.2-0.5 parts by weight of titanate coupling agent, 0.2-0.5 parts by weight of zirconate coupling agent, 15-25 parts by weight of acrylic copolymer emulsion, and 5-10 parts by weight of microencapsulated active aggregate. The microencapsulated active aggregate consists of a core material and a wall material. The core material is ultrafine active silica or metakaolin powder, and the wall material is a polymer material that can be slowly dissolved in alkali.

[0040] In step S4, the mesh fabric is laid flat on the grooved surface of the leveling layer, with the raised grooves facing downwards and aligned with the groove. Adjacent edges overlap by 50mm and are fixed with epoxy mortar. A closed annular gas collection pipe is fixed along the perimeter of the entire mesh fabric using a pressure strip. Air intakes are made downwards every 300mm along the pipe, directly facing the end of the groove or the intersection of the grooves below. The joint between the gas collection pipe and the ground is temporarily sealed with sealing tape to prevent air leakage. The gas collection pipe is connected to an outdoor vacuum pump via a flexible hose. The three data points marked on the wall are used to confirm whether the overall condition meets the laying requirements.

[0041] In step S4, after starting the vacuum pump, the negative pressure value is maintained at -0.02 to -0.04 MPa continuously until the next step of applying the intermediate coating slurry begins. This negative pressure continuously extracts residual moisture and air from the leveling layer and primer, while simultaneously causing the microcapsule wall material to develop micro-cracks under continuous negative pressure suction, placing it in a metastable state awaiting activation. At the same time, the adsorption force tightly presses the mesh cloth against the bottom surface of the groove, ensuring that the air guiding groove is not flattened, thus reserving a continuous channel for the rapid penetration of the subsequent slurry.

[0042] In step S5, within 5 minutes of turning off the vacuum pump, pour the high-solids epoxy intermediate coating slurry onto the mesh fabric and apply the first coat with an elastic scraper to a thickness of approximately 2 mm. The alkaline components in the slurry contact the microcapsule wall material's microcracks, causing it to slowly dissolve and release active silica that chemically integrates with the epoxy. Simultaneously, the residual suction from the previous negative pressure actively draws the slurry into the bottom of the grooves and the tips of the cracks, achieving complete filling without dead corners. After application, remove the gas collection pipe and pressure strip, seal the fabric edges with the same slurry, and then smooth the surface in the same direction. Let the intermediate coating stand for 40 to 60 minutes, and immediately proceed with the topcoat application when it is no longer sticky to the touch. The time recorded on the wall is used to calibrate the accuracy of this window period.

[0043] In step S6, during the gel window of the intermediate coat, the self-leveling epoxy topcoat material is mixed according to the formula and thoroughly stirred to remove bubbles. It is then evenly poured onto the intermediate coat surface, using a trowel to control the topcoat thickness to 1.0 to 1.5 mm. Immediately after pouring, a toothed defoaming roller is used to slowly roll back and forth to break up internal air bubbles, maintaining a constant speed. Because the intermediate coat is not yet fully cured, the reactive diluent in the topcoat can chemically cross-link with the residual active groups in the intermediate coat, forming a molecular-level bond without the need for an additional interface agent. Upon completion of the topcoat, the ambient temperature, relative humidity, and completion time are marked on the wall surface as a basis for subsequent curing adjustments. This record, together with the previous wall surface data, constitutes a complete construction log.

[0044] In step S7, the air conditioning system should be shut off within 24 hours after the topcoat application. The ground should be undisturbed, the ambient temperature maintained between 20 and 25°C, and the relative humidity below 75%. The temperature and humidity values ​​marked on the wall should be checked and recorded every 8 hours. During the curing period, no footsteps or objects should be placed on the surface. After 48 hours of curing, wipe all areas of the surface with a damp cotton cloth and observe for any water seepage, discoloration, or damp marks to confirm adequate impermeability. Then, perform light mechanical polishing to remove small particles and measure the surface resistance using an electrostatic tester to ensure it meets anti-static requirements. Finally, remove all temporary markings and whiteboard records from the wall, clean the tools, and hand over the work area along with the temperature and humidity verification records from the curing period to the user.

[0045] Comparative Example: Traditional Layered Construction Method for Epoxy Flooring in Pharmaceutical Cleanrooms: A pharmaceutical company chose the most common bisphenol A type epoxy resin flooring system for its cleanroom, and the specific implementation is as follows: The substrate was roughened by shot blasting, rinsed with water, and allowed to air dry for approximately 36 hours. Moisture content was not measured using instruments; it was considered acceptable simply by touch if no obvious moisture was detected. Cracks were filled with ordinary epoxy putty, and the smoothness was not checked with a 2-meter straightedge after filling. The lack of quantitative moisture content testing and smoothness calibration in this step directly led to residual moisture migrating upwards during the subsequent coating curing process and insufficient contact between the substrate and the primer. These data discrepancies will be addressed later. Figure 2 This is reflected in the corresponding text.

[0046] For the primer application, mix the solvent-based epoxy primer with the hardener at a ratio of 4:1, dilute with 10% acetone, and apply one coat by roller, with a coverage rate of 0.12 kg / m². 2 The primer was allowed to cure naturally for 8 hours until surface dry, during which time the ambient temperature and humidity were not controlled. The leveling layer was applied directly after the primer cured, without proceeding to the next step within the surface drying window. This resulted in a lack of chemical affinity between the primer and the leveling layer, relying solely on mechanical anchoring for bonding. The difference in interfacial bonding caused by this step is shown in [see figure]. Figure 2 .

[0047] The leveling layer was constructed by applying a 4 mm thick layer of epoxy mortar, which was then rolled back and forth with a defoaming roller to eliminate large air bubbles. The surface was only smoothed without any grooves or grooves. After 24 hours of natural curing, it was sanded rough with an angle grinder and cleaned three times with a damp mop. Because the leveling layer surface was flat and dense without air channels, the air bubbles trapped inside during curing could not escape. These trapped air bubbles expanded when heated during use, forming bulges. This defect is related to… Figure 3 The bubble residue rate of 22% and the blistering rate of 7.8% in the comparative example directly correspond.

[0048] The mesh fabric used for laying is commercially available ordinary alkali-free fiberglass mesh. This fabric has no raised structures at the intersections of the warp and weft threads, and the surface has only a single layer of polyacrylate waterproof coating. The unit area mass is 120 g / m². 2 The overlap is 40 mm, fixed with epoxy putty, and then rolled and adhered with a metal roller. Because the leveling layer surface is flat and lacks grooves for guidance, there are large unsupported areas between the mesh and the leveling layer. The intermediate coat slurry cannot fill these gaps, and this problem manifests in… Figure 3 The medium-sized mesh fabric has a porosity of 17% and a crack linear density of 2.3 m / m. 2 .

[0049] During the intermediate coating application, a 2 mm thick layer of high-solids epoxy slurry was applied and allowed to cure naturally for 12 hours. Inspection revealed multiple pinholes and air bubbles with diameters ranging from 0.5 to 1 mm. These were locally repaired with the same slurry and cured for another 4 hours before being sanded and cleaned of dust. The pinholes and air bubbles were caused by a lack of negative pressure guidance, preventing the slurry from penetrating the gaps beneath the mesh fabric. The repair process only covered surface defects and was ineffective against deeper voids. This step is related to… Figure 3The data is directly related to the fact that the medium-strength water pressure is only 0.5 MPa and the water completely leaks after holding the pressure for 60 minutes.

[0050] After the intermediate coat has fully cured, apply one coat of epoxy interface agent at a dosage of 0.08 kg / m². 2 Wait 4 hours for surface drying. For the topcoat application, pour a 1.2 mm thick self-leveling epoxy topcoat, spread it with a trowel, and then defoam it with a roller. Allow it to cure naturally for 48 hours. During curing, only enclosure was used; temperature and humidity were not controlled. The presence of the interface agent layer itself constitutes a physical interface; the topcoat and intermediate coat are bonded by physical adhesion rather than chemical bonding. See [link to comparison]. Figure 2 The adhesion strength between the topcoat and intermediate coat was 2.3 MPa. Inadequate temperature and humidity control during curing led to insufficient curing of the topcoat, resulting in a water absorption weight gain of 0.58% and a water vapor permeability coefficient of 8.7 × 10⁻⁶ after long-term use. -12 The g / m·s·Pa value is too high; see the following section for further details. Figure 3 The entire construction period was 8 days, including 4 waiting processes. This efficiency loss was concentrated in [the following text is missing from the original] Figure 4 .

[0051] The differences between the comparative data and the data of this process are clearly mapped to each construction step. Figure 2 The comparative example showed an interlayer pull-out strength of only 2.1 MPa, while this process achieved 5.6 MPa. The difference stems from the fact that the chemical anchoring formed by the microcapsule-triggered release in this process replaced the physical bonding in the comparative example. At the same time, the topcoat and intermediate coat directly chemically cross-link during the gelation window, eliminating the need for an interface agent layer and removing all three weak points at the interface. Figure 3 The comparative sample showed a bubble residual rate of 22%, a porosity of 17%, and a water pressure resistance of only 0.5 MPa, with complete leakage after holding the pressure for 60 minutes. In contrast, the three data points of this process were 0.5%, 0.3%, and 1.5 MPa, respectively, with no leakage after holding the pressure for 60 minutes. The root cause of the improvement lies in the groove alignment and micro-negative pressure active venting, which forces the closed bubbles and suspended areas to be discharged, thus cutting off the capillary leakage path. Figure 4 The comparison showed a construction cycle of 8 days and a maintenance interval of 6 months, while this process had a cycle of 4 days and a maintenance interval of over 36 months, while labor hours were reduced from 1.8 h / m. 2 Reduced to 0.9 h / m 2 Material consumption from 4.2 kg / m 2 Reduced to 3.6 kg / m 2 The overall cost is actually lower than the comparison ratio. This benefit comes from the time and material savings from eliminating four waiting processes and applying interface agent, as well as the long-term durability improvement brought about by the chemical cross-linking integrated structure.

[0052] It should be noted that, in this document, relational terms such as "first" and "second" are used merely to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the term "comprising" or any other variations thereof is intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or apparatus. Without further limitations, an element defined by the phrase "comprising one..." does not exclude the presence of other identical elements in the process, method, article, or apparatus that includes the element.

[0053] The above embodiments are only used to illustrate the technical solutions of the present invention, and are not intended to limit it. Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some of the technical features. Such modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of the present invention.

Claims

1. A seamless anti-seepage construction process for cleanroom floors in pharmaceutical manufacturing facilities, characterized in that: The method includes the following steps: S1: Clean and repair the base layer, sand it to a solid surface, rinse and dry it, measure the moisture content and record it on the wall surface; S2: Roller-apply penetrating primer, mark the surface drying time, and scrape the leveling layer after surface drying. S3: Scrape the epoxy mortar leveling layer to the design thickness, and before initial setting, use a nail-notched trowel to pull out a shallow groove and measure and mark the thickness; S4: Lay alkali-resistant glass fiber mesh cloth. The cloth is based on high zirconium glass fiber, with an inner layer coated with nano-montmorillonite modified acrylic acid and an outer layer coated with an acrylic coating containing microencapsulated active silica by electrostatic gradient spraying. The microcapsule wall material is a polymer that is slow to dissolve in alkali. Lay the mesh fabric flat on the grooved surface of the leveling layer, with the raised air guide grooves facing down and aligned with the grooves. Overlap adjacent fabric edges by 50mm. Secure a closed annular air collection pipe along the perimeter of the entire mesh fabric using pressure strips. Open air intakes every 300mm along the pipe, with the air intakes facing the end or intersection of the grooves below. Temporarily seal the gap between the air collection pipe and the ground with sealing tape. Connect the air collection pipe to the outdoor vacuum pump via a flexible hose. Start the vacuum pump and maintain a negative pressure of -0.02 to -0.04 MPa. Continue to maintain this negative pressure until the next step of applying the intermediate coating slurry begins. This negative pressure not only continuously extracts residual moisture and air from the leveling layer, but also causes the microcapsule wall material to develop fine cracks and be in an activated state. At the same time, the negative pressure adsorption force tightly presses the mesh cloth to the bottom of the groove, ensuring that the air guide groove is not flattened, thus reserving a continuous channel for the rapid penetration of the subsequent slurry. S5: Within 5 minutes after the vacuum is turned off, apply a high-solids epoxy intermediate coating. The alkaline slurry triggers the dissolution of the microcapsule wall material, releasing active silicon powder and chemically intercalating with the epoxy. At the same time, the negative pressure difference causes the slurry to be drawn into the groove and filled. After leveling, let it stand until it is no longer sticky to the touch. S6: Gel window inner pour self-flowing surface coating, defoaming roller breaks bubbles, two layers chemically cross-linked into a whole; S7: After 48 hours of curing, wipe with a damp cloth to ensure no water seepage, polish, measure resistance, and hand over if qualified.

2. The seamless anti-seepage construction process for cleanroom floors in pharmaceutical cleanrooms according to claim 1, characterized in that: In step S1, the base layer is cleaned to remove the ground laitance, oil stains and loose layer, and then sanded with an angle grinder until a solid base surface is exposed. After rinsing with a high-pressure water gun, it is naturally air-dried until there are no obvious water marks on the surface. For cracks and depressions wider than 0.2mm, fill and smooth them with epoxy putty. Then use a 2m straightedge to check the flatness and ensure that the maximum gap is no more than 2mm.

3. The seamless anti-seepage construction process for cleanroom floors in pharmaceutical cleanrooms according to claim 1, characterized in that: In the step S2, the low viscosity epoxy primer material is mixed in proportion, and is applied to the surface of the base layer by a short hair cylinder in the same direction, with the coating amount controlled to be 0.15-0.20 kg / m 2 .

4. The seamless anti-seepage construction process for cleanroom floors in pharmaceutical cleanrooms according to claim 1, characterized in that: In step S3, while the primer is still partially dry, the epoxy mortar leveling material is poured onto the ground and continuously scraped with a notched scraper to a designed thickness of 3 to 5 mm, with an overlap of at least 100 mm between each scraping strip. Immediately after scraping, while the mortar is still in its plastic, pre-setting stage, shallow grooves are pulled vertically with a special notched trowel. The grooves are about 0.5 mm deep and spaced about 20 mm apart. The grooving operation must be completed before the mortar begins to set.

5. The seamless anti-seepage construction process for cleanroom floors in pharmaceutical cleanrooms according to claim 1, characterized in that: In step S4, the alkali-resistant glass fiber mesh fabric formulation includes: 60-70 parts by weight of silica, 8-10 parts by weight of calcium oxide, 5-8 parts by weight of magnesium oxide, 0-5 parts by weight of aluminum oxide, 0-3 parts by weight of titanium dioxide, 0.5-5 parts by weight of zirconium oxide, the balance of alkali metal oxides, 20-30 parts by weight of modified acrylic copolymer emulsion, 1-3 parts by weight of nano-montmorillonite, 0.2-0.5 parts by weight of titanate coupling agent, 0.2-0.5 parts by weight of zirconate coupling agent, 15-25 parts by weight of acrylic copolymer emulsion, and 5-10 parts by weight of microencapsulated active aggregate. The microencapsulated active aggregate consists of a core material and a wall material. The core material is ultrafine active silica or metakaolin powder, and the wall material is a polymer material that can be slowly dissolved in alkali.

6. The seamless anti-seepage construction process for cleanroom floors in pharmaceutical cleanrooms according to claim 1, characterized in that: In step S4, the mesh fabric is laid flat on the grooved surface of the leveling layer, with the raised grooves facing down and aligned with the grooves. Adjacent edges of the fabric overlap by 50mm and are fixed with epoxy mortar. A closed annular gas collection pipe is fixed along the perimeter of the entire mesh fabric with pressure strips. Air intakes are opened every 300mm downwards on the pipe, with the air intakes facing the end of the groove below or the intersection of the grooves. The joint between the gas collection pipe and the ground is temporarily sealed with sealing tape to prevent air leakage. The gas collection pipe is connected to the outdoor vacuum pump through a flexible hose. The three data points marked on the wall are used to confirm whether the overall condition meets the laying conditions.

7. The seamless anti-seepage construction process for cleanroom floors in pharmaceutical cleanrooms according to claim 1, characterized in that: In step S4, after starting the vacuum pump, the negative pressure value is maintained at -0.02 to -0.04 MPa without interruption until the next step of applying the intermediate coating slurry begins.

8. The seamless anti-seepage construction process for cleanroom floors in pharmaceutical cleanrooms according to claim 1, characterized in that: In step S5, within 5 minutes after the vacuum pump is turned off, the high-solids epoxy intermediate coating slurry is poured onto the mesh cloth, and the first intermediate coating is applied with an elastic scraper to a thickness of about 2mm. The alkaline components in the slurry contact the microcracks in the microcapsule wall material, causing it to slowly dissolve and release active silica to chemically intercalate with the epoxy. At the same time, the suction force of the previous negative pressure actively draws the slurry into the bottom of the groove and the tip of the crack, achieving filling without dead corners.

9. The seamless anti-seepage construction process for cleanroom floors in pharmaceutical cleanrooms according to claim 1, characterized in that: In step S6, during the gel window period of the intermediate coating, the self-leveling epoxy topcoat material is mixed according to the formula and stirred thoroughly to remove bubbles, and then poured evenly onto the surface of the intermediate coating. The thickness of the topcoat is controlled to be 1.0 to 1.5 mm using a trowel.

10. The seamless anti-seepage construction process for cleanroom floors in pharmaceutical manufacturing facilities according to claim 1, characterized in that: In step S7, the air conditioning system shall be turned off within 24 hours after the topcoat is applied, the ground shall be kept undisturbed, the ambient temperature shall be maintained at 20 to 25°C, and the relative humidity shall be below 75%. The temperature and humidity values ​​marked on the wall shall be checked and recorded every 8 hours. During the curing period, no items shall be stepped on or piled up. After 48 hours of curing, wipe all areas of the surface with a cotton cloth moistened with clean water and observe for any water seepage, discoloration or damp marks to confirm that the impermeability is qualified.

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