Selecting Appropriate Flooring Based on Lab Usage and Scope

When designing highly technical spaces such as labs and cleanrooms, it can be easy to put off finish selection to the end of the process. At a high level, it may seem that the finishes are purely for aesthetics and are only accessories to the functionality of the space. However, this is misinformed, as finish selection can have a direct impact on the functionality and cleanliness of the environment. Some guidelines set specific expectations for finish selection and installation (such as the USP General Chapters), while other spaces have tried and true best practices that are not necessarily depicted by specific codes or guidelines. In this exploration, some key elements to flooring selection are addressed, as well as how the function of the space can indeed be impacted by the design of the flooring patterns.  

Understanding the design target

The first step in any finish selection process is understanding who the current client is and who the ultimate end user will be. An example where these entities may not be the same is in the situation where a developer may be designing a lab space for a future lab tenant, but that tenant is not currently involved in the design process. Once the interested parties are identified, the current and future goals can be set for the flooring selection. 

Expanding on the above scenario, if a developer assumes that the future tenant would be operating in a BSL-2 environment but isn’t sure whether they would prefer a rolled vinyl product versus a tile vinyl product, perhaps she will choose to leave the subfloor exposed as a prepared concrete surface so that the end user can select the exact finish flooring product to meet their needs.

Alternatively, the developer may elect to install a static dissipative resilient tile, which is a very versatile product that will meet most BSL-2 needs, to have the space ready for move-in on day one. Understanding the current and potential future needs of the space can help ensure that the design doesn’t result in a waste of material or funds, due to not considering the lifetime use of the lab and requirements of the parties involved.

Flooring preparation and selection

Expanding further upon the idea of preparing the subfloor for future flooring selections, flooring preparation is crucial in the final appearance and performance of a floor. 

Clearly, the desire for most flooring applications, whether they are in laboratories or offices, is for them to be level and generally not sloped. However, the level of tolerance is typically lower in lab environments. One factor to consider is whether the lab will have tables or fixed casework. With tables, if there are some pockets and imperfections in the flooring, the legs and feet of most tables can be adjusted to accommodate these variances and still remain level and at a standard height throughout the lab. However, fixed casework is less forgiving. When maintaining a level counter surface over long runs, if there is a noticeable slope or any large divots in the flooring, you will notice large gaps forming at the base of the casework. While a resilient rubber base can be applied to block these gaps, it provides a less stable surface to push mops and other cleaning apparatuses up against. Therefore, it is highly recommended to prepare and level the subfloor before applying finish flooring in applications where fixed casework will be used; an example of this preparation would be using a cementitious self-leveling agent throughout the entirety of the space. This will add cost to the project but will add value in aesthetics and performance of the finished space. A cost-benefit analysis should be performed on all projects before making such decisions, so it is important for the client and/or end user to have these conversations with the architect at the beginning of a project to ensure appropriate decisions are made for the project’s budget and use.

Once the end user is established for a space, it is important to understand their cleanliness requirements and intended usage. For lab settings, it can be assumed that a non-grooved resilient flooring material will be used for easy cleaning and spill cleanup. However, specific environments have more stringent requirements around dust mitigation and cleaning standard operating procedures (SOPs). As a point of comparison, for most BSL-2 wet labs, a resilient rubber base used at the perimeter of the space and at the point of fixed casework will be sufficient in preventing floor debris from getting trapped behind crevasses and absorbed into a porous wall substrate. However, an ISO-7 cleanroom space will not only require an integrated cove base to prevent any dirt from gathering at the crease between the flooring and the base, but it also should not have a ledge at the top of the base, which can collect dust. This means that the floor design then feeds into the wall design, whether that is with modular panels or stick-built construction with studs and gypsum board. 

Furthermore, while a seamless rolled flooring product may be appropriate in this setting if the space is going to be exposed to harsh chemicals or frequent moisture, an epoxy resin floor will be a more appropriate selection with better performance and a longer lifespan.

An example of where epoxy resin floors would be the preferred choice would be in a vivarium environment due to the moisture exposure and disinfection requirements.  

Functional design

The final item to address in this brief introduction to flooring selection is the design of the flooring itself. In any design process, once a flooring product is selected, a color and/or pattern will also need to be selected and specified for installation. However, the installation pattern of flooring can accomplish more than simply adding aesthetic interest to the space. 

Different flooring selections and seam placement can, in fact, help demarcate the SOPs for the end users. 

For example, instead of applying an adhesive step-over line in cleanroom ante-rooms, the design team can specify that one color of flooring is used on the dirty side of the line, and a different color is used on the clean side, and subsequently, throughout the rest of the clean space. This is not only a more aesthetically pleasing solution, but it also helps maintain better cleanliness in the lab by removing the raised seam and adhesive that is introduced in the option that is applied after construction.

Another example of this would be creating a hazardous drug storage area within a USP <800> compliant compounding pharmacy or demarcating different departments within an open-plan lab space. The selection and application of flooring not only have to perform well from a chemical standpoint but also from an aesthetically functional standpoint.

The above only scratches the surface of flooring selection, but highlights some high-level concepts to consider when engaging in the finish selection design process for lab and cleanroom spaces. It is important to consider the long-term use of the lab, functionality, budget, cleanliness, and functional aesthetics as a starting point. Open dialogue with the client and/or end users from the start of a project can help ensure the desired design intent for the flooring selection is met while also meeting the rest of the project’s goals.