Case Study 1: Pharmaceutical Manufacturing Clean Room

Project Overview

• Client: Mid-Atlantic pharmaceutical manufacturer
• Facility: 75,000 sq ft clean room production area
• Challenge: Upgrade to ISO Class 7 clean room standards while minimizing production downtime
• Timeline: 6 weeks phased implementation
• Investment: $245,000

Specific Challenges

• Existing epoxy coating system failed particle count requirements
• Production shutdown limited to weekend periods only
• FDA validation required for all materials and processes
• Temperature and humidity control during application critical

Solution Implemented

• System selected: Two-component polyurethane clean room coating with antimicrobial additives
• Surface preparation: Diamond grinding to remove existing coating, achieving CSP 2-3 profile
• Application process: Phased room-by-room approach with temporary barriers
• Quality control: Real-time particle counting and surface testing

Measurable Results

• Particle count reduced from 352,000 to 8,500 particles per cubic meter (98% improvement)
• Zero production days lost (all work completed during scheduled downtime)
• Passed FDA validation on first attempt
• Annual cleaning costs reduced by $42,000 due to improved cleanability
• Three-year warranty provided with expected 10+ year lifespan

Case Study 2: Food Processing Plant Floor Restoration

Project Overview

• Client: Southwest regional meat processing facility
• Facility: 120,000 sq ft production floor with daily washdowns
• Challenge: Replace failed coating system while maintaining USDA compliance and production schedule
• Timeline: 8-week phased implementation
• Investment: $385,000

Specific Challenges

• Existing coating system delaminating from thermal shock (freezers to processing areas)
• Chemical damage from caustic washdown solutions and organic acids
• 24/6 production schedule (Sundays only for coating application)
• USDA inspection requiring FDA-compliant materials

Solution Implemented

• System selected: Novolac epoxy with polyurethane topcoat, 40-mil total thickness
• Surface preparation: Complete removal of existing coating via shotblasting
• Application strategy: Fast-cure formulation allowing 12-hour return to service
• Special features: Anti-slip aggregate, cove base system, integrated floor drains

Measurable Results

• Coating system performing excellently after 18 months with no delamination
• Chemical resistance testing shows no degradation from daily washdowns
• Thermal cycling tests confirm adhesion through -20°F to 70°F transitions
• Slip resistance improved from 0.42 to 0.68 coefficient of friction (62% improvement)
• Floor maintenance time reduced by 35% due to improved cleanability
• Zero production interruptions beyond scheduled Sunday maintenance windows

Case Study 3: Chemical Manufacturing Tank Farm

Project Overview

• Client: Gulf Coast petrochemical facility
• Facility: 24 storage tanks ranging from 10,000 to 100,000 gallons
• Challenge: Restore corrosion-damaged tanks while maintaining chemical storage operations
• Timeline: 16-week rolling implementation
• Investment: $520,000

Specific Challenges

• Salt air corrosion combined with chemical spills created extensive surface damage
• Confined space entry requirements for interior coating application
• High summer temperatures (100°F+) affecting coating application and cure
• Regulatory compliance for VOC emissions and waste disposal

Solution Implemented

• Exterior system: Three-coat epoxy polyamide system with moisture-cure topcoat
• Interior system: Chemical-resistant novolac epoxy with amine cure
• Surface preparation: UHP water jetting (10,000 PSI) to SSPC-SP12/NACE 5 standard
• Application strategy: Two-tank rotation maintaining operational capacity

Measurable Results

• All tanks returned to service with zero chemical compatibility issues
• Corrosion protection testing predicts 15-20 year service life
• Facility maintained 85% operational capacity throughout project
• Coating system passed third-party inspection for insurance requirements
• Annual tank maintenance costs reduced from $125,000 to $18,000 (86% reduction)

Case Study 4: Distribution Center Floor Coating

Project Overview

• Client: Major e-commerce fulfillment center
• Facility: 500,000 sq ft warehouse with 24/7 operations
• Challenge: Install traffic-rated floor coating without operational shutdown
• Timeline: 12-week phased implementation
• Investment: $625,000

Specific Challenges

• Continuous operations precluded facility-wide shutdown
• Heavy forklift traffic (200+ lifts operating simultaneously)
• Stringent slip resistance requirements for pedestrian safety
• Color-coded zone marking system for operational efficiency

Solution Implemented

• System selected: Fast-cure polyurea coating with 12-hour return to service
• Surface preparation: Mechanical abrading with HEPA vacuum dust control
• Application strategy: Zone-by-zone implementation during shift changes and weekends
• Safety markings: Color-coded system with retroreflective striping

Measurable Results

• Project completed with zero operational downtime
• Floor lighting reflectivity improved 40% reducing supplemental lighting needs
• Workplace injuries decreased 28% due to improved visibility and slip resistance
• Annual floor maintenance costs reduced from $85,000 to $22,000 (74% reduction)
• Coating system showing excellent performance after 14 months under heavy traffic

Key Success Factors Across All Projects

Strategic Planning

• Comprehensive surface evaluation and testing before system selection
• Phased implementation strategies maintaining operational requirements
• Contingency planning for weather, equipment failure, and schedule conflicts

System Selection

• Performance specifications based on actual operational conditions
• Life-cycle cost analysis rather than lowest initial cost
• Proven track record in similar applications

Execution Excellence

• Certified applicators with specialized training
• Quality control testing at each application stage
• Complete documentation for validation and future reference

Conclusion

These case studies demonstrate that successful industrial coating projects require more than premium materials—they demand strategic planning, appropriate system selection, and expert execution. By learning from real-world applications, facility managers can make informed decisions that deliver measurable performance improvements and long-term value.

Explore our complete case study library for additional project examples and industry-specific applications.