A complete guide to building a modular cleanroom
In today’s rapidly evolving manufacturing and research environments, clean and controlled spaces are essential. A modular cleanroom provides an effective solution for industries from pharmaceuticals to electronics and biotechnology.
This complete guide will walk you through everything you need to know about building a modular cleanroom. We focus on design, planning, construction and operational considerations. We also explain why cleanroom systems and prefab cleanrooms are strong options for many companies.
If you are exploring modular cleanroom manufacturers, this guide will help you ask the right questions and make informed decisions.
What is a modular cleanroom?
A modular cleanroom is a controlled environment designed to maintain low levels of airborne particles, temperature, humidity and other key contamination factors. Unlike traditional stick-built cleanrooms, modular cleanroom systems use prefabricated panels and systems. These systems are engineered for quick assembly and flexibility. Like regular cleanroom systems, modular cleanrooms, too, are designed to meet various cleanliness standards such as ISO classifications.
Modular cleanrooms are built using high-quality panels, framing and fixtures that snap together or are bolted on site. The result is a space that meets stringent requirements while offering scalability and cost savings. These cleanrooms are ideal for facilities that need flexibility and rapid deployment, all without compromising on quality, structural integrity, and regulatory compliance.
Why choose a modular cleanroom?
Across many industries, there are several reasons companies choose a modular cleanroom over traditional construction. Here are some of the most common advantages that compel them to go the modular route:
Speed of construction
Modular cleanrooms or prefabricated cleanrooms can be built much faster than traditional cleanrooms. They are manufactured offsite and assembled onsite. This reduces lead times and minimises disruptions to your existing operations. When time to operation is critical, a modular cleanroom is often the best choice. So, it’s not surprising that as industry gets more competitive, research and manufacturing players are increasingly eager to invest in modular cleanroom systems.
Cost effectiveness
Building a modular cleanroom typically costs less than conventional construction. The prefabrication process reduces labour costs and construction waste. It cuts short timelines. Moreover, cleanroom systems are optimised to reduce unnecessary components and simplify installation. The result? Lower overall project costs while still meeting industry standards.
Flexibility and scalability
One key benefit of modular design is flexibility. If your needs change over time, you can modify the cleanroom without major renovations. Panels can be reconfigured, new sections can be added, and systems can be upgraded. Modular cleanrooms can even be portable. This makes modular cleanrooms ideal for growing companies and evolving industries. In a world constantly in flux, especially with dynamic environmental and economic conditions, modular or prefabricated cleanrooms are ideal for most businesses.
Quality and compliance
Modular cleanrooms are manufactured to meet strict quality standards. Given that the cleanroom panels are manufactured in controlled factory settings, quality control and assurance become a lot easier compared to quality control at traditional construction sites.
Reputable modular cleanroom manufacturers use consistent processes to ensure performance and compliance. These cleanrooms can (and should) be certified to meet ISO and other industry specific standards. This gives you confidence that your cleanroom environment will meet regulatory requirements.
Core components of modular cleanroom systems.
Understanding the major components of a modular cleanroom can help you plan and design a system that meets your needs. Here are the essential parts:
Wall and ceiling panels
Wall and ceiling panels form the enclosure of the cleanroom. These panels are usually made with a steel or aluminium frame and a high-density core for insulation and rigidity. Surfaces are smooth and easy to clean, which helps maintain low contamination levels.
Flooring
The floor of a modular cleanroom must support cleaning and withstand heavy traffic. Options include vinyl epoxy and conductive flooring depending on your industry needs. Flooring is installed with special care to eliminate seams and reduce particle build-up.
Filtration and airflow systems
Cleanrooms require controlled airflow to maintain a consistent internal environment. High-efficiency particulate air filters, or HEPA filters, are typically used. These filters remove particles from the air to a degree that meets cleanliness standards. Proper airflow design is essential to avoid contamination and ensure consistent performance. This applies equally to traditionally built and modular cleanroom systems.
Lighting
Lighting in modular cleanrooms is designed for optimal visibility without introducing contaminants. Fixtures are sealed and easy to clean. Lighting options vary by classification and application.
Doors and windows
Cleanroom doors and windows are built to preserve environmental control. Doors are often sliding or swing type with airtight seals. Windows are constructed to resist fogging and contaminant transfer. Proper design and material selection help maintain pressure differentials and visibility.
Controls and monitoring
Environmental sensors monitor temperature, humidity, pressure, and particles in the air. These controls ensure the cleanroom meets required conditions. Some systems include automated alerts and integrated software to help manage compliance. You should ask your modular cleanroom manufacturer about the monitoring systems that will best suit your requirements.
Building a modular cleanroom is a complex, multi-faceted project, but the results are well worth the investment. You will have to spend considerable effort in design and planning, but once the fabrication and construction processes are underway, things move far more smoothly than traditional construction ever could. And throughout the life cycle of your facility, you will have unparalleled control and flexibility when it comes to layout, reconfiguration, and scaling up.
Now that you have a brief understanding of the components that make up a modular cleanroom, in part two, we’ll dive into the planning process. If setting up a prefabricated cleanroom is on the cards for you, you don’t want to miss it.
Building a modular cleanroom is no piece of cake. But with the right planning and support from competent modular cleanroom manufacturers, you can streamline the process and enjoy gains in terms of efficiency, productivity, and cost-savings unlike anything you will get from traditional construction.
So, let’s jump into it: how do you plan your modular cleanroom to make the most of this construction technology?
Planning your modular cleanroom.
Effective planning is the foundation of a successful modular cleanroom. A poorly planned cleanroom can result in operational issues higher costs and delays. Here are the key steps in planning to make the most of your prefabricated cleanrooms:
Define your cleanroom requirements. Start by identifying what you need from the cleanroom. Ask questions such as:
- What level of cleanliness is required?
- What industry standards must be met?
- What processes will occur inside the cleanroom?
- How many people will use the space?
These questions help determine the classification, size, layout, and systems needed.
Select the right classification. Cleanrooms are classified by the permitted number of particles per volume of air. The most common standards are ISO classifications. The ISO class you choose depends on your industry and processes. For example, cleanrooms for pharmaceutical manufacturing often require stricter classifications than general assembly work.
Choose a layout that fits your workflow. Your cleanroom layout should support efficient movement of people, materials, and products. Think about entry and exit points, gowning areas, equipment placement, and storage. An optimised layout minimizes cross contamination and improves productivity.
Assess utilities and infrastructure. A modular cleanroom still needs utilities such as electrical power, compressed air, and HVAC connections. Early assessment of your existing infrastructure can help prevent delays during installation. You can also have integrated utility distribution in your modular cleanroom. Discuss your options with your modular cleanroom manufacturers.
Create a budget and timeline. Work with your stakeholders to define your budget and schedule. Include contingencies for delays and unexpected changes. A clear budget and timeline keep your project on track.
Selecting a modular cleanroom manufacturer.
Choosing the right modular cleanroom manufacturer is one of the most important decisions you will make. The manufacturer you select will determine the quality, durability, and compliance of your cleanroom systems. Here are tips to help you choose:
Experience and expertise
Look for modular cleanroom manufacturers with proven experience in your industry. An experienced manufacturer understands industry-specific challenges and regulatory requirements. They can provide insights and recommendations based on real project experience.
Customisation capabilities
Every cleanroom project is unique. Your manufacturer should be able to customise panels, systems and components to meet your design needs. Avoid one-size-fits-all solutions when your requirements are specific.
Quality assurance and certifications
Ask about the quality standards the manufacturer follows. Do they have ISO certifications? How do they ensure panel and system performance? A manufacturer with strong quality assurance practices delivers more reliable cleanrooms. For instance, when it comes to PodTech™’s modular cleanroom systems, quality control is built into the process, so you, as a facility manager, owner or operator, have less to worry about.
Installation and support services
Some manufacturers offer end-to-end services including design, consultation, installation, and ongoing support. This can simplify your project and ensure seamless implementation. Make sure you understand the level of support provided before committing.
References and reviews
Ask for references from past clients. Reviews and case studies can help you understand how the manufacturer performs on real projects. This insight can be valuable when making your selection.
Construction and installation of a modular cleanroom.
Once planning is complete and you have selected a manufacturer, the next step is construction and installation. Here is what to expect:
Site preparation
Before installation begins, your site must be prepared. This includes clearing the area, ensuring utilities are accessible, and verifying the structural floor supports are adequate. A prepared site reduces installation time and prevents issues later on in the installation and operation phases of your project.
Panel delivery and staging
Prefabricated cleanroom panels and components are delivered to your site. These parts are staged (the way in which delivered cleanroom components are received, organised, and positioned on-site) for efficient installation. Proper staging is important for keeping the workflow organised and avoiding damage.
Assembly and installation
Installation typically begins with the framing and floor systems. Walls, ceilings and doors are assembled next. HVAC and filtration systems are integrated as the structure takes shape. Skilled technicians ensure each component meets design specifications.
Inspection and testing
After assembly, the cleanroom is inspected and tested. Airflow, temperature, humidity, and particle counts are measured until they meet the required standards. Proper commissioning is essential for certification.
Certification
Many industries require certification before operations can begin. A certified cleanroom confirms that the space meets required regulatory standards. Certifications are performed by third-party inspectors and documented for compliance.
Operational considerations for cleanroom systems.
Building a modular cleanroom is only part of the journey. You must also maintain operations at a certain level to ensure longevity and compliance. Here are key operational considerations:
Standard operating procedures
Develop clear standard operating procedures or SOPs for all cleanroom activities. SOPs should address entry and exit protocols, cleaning routines, equipment use, and emergency procedures. Well-documented procedures help maintain cleanliness and reduce errors.
Training and gowning
Personnel must be trained on cleanroom protocols and contamination control. Training includes proper gowning techniques, movement restrictions, and hygiene practices. Staff compliance with training helps prevent contamination events.
Cleaning and maintenance
Routine cleaning is critical in a cleanroom. Use approved cleaning agents and tools to protect surfaces and filters. Maintenance of HVAC and filtration systems ensures your cleanroom remains functional and compliant.
Monitoring and quality control
Continuous monitoring of environmental conditions helps detect issues early. Use particle counters and environmental sensors to verify cleanliness. Implement corrective actions quickly when parameters deviate from standards.
Upgrades and scalability
As your needs change, you may need to expand or upgrade your cleanroom systems. Modular cleanroom design makes it easier to add new sections, upgrade filters, or change layouts. Plan for flexibility to support future growth.
Common mistakes to avoid when building a modular cleanroom.
Even with careful planning mistakes can happen. Here are some pitfalls to avoid:
Inadequate planning
Failing to define requirements or underestimating needs can lead to costly changes later. Take time upfront to plan thoroughly with all stakeholders.
Ignoring workflows
A cleanroom that does not support logical workflows will hinder productivity. Design layouts that promote efficient movement and minimise contamination risks.
Poor selection of modular cleanroom manufacturers
Choosing the cheapest manufacturer without evaluating quality and experience can result in a subpar cleanroom. Invest time in selecting a reputable partner.
Neglecting maintenance
A cleanroom requires ongoing care. Ignoring maintenance can result in degraded performance and compliance issues. Establish a maintenance schedule and stick to it.
Lack of training
Even the best cleanroom will fail if staff are not trained properly. Invest in training and reinforce protocols regularly.
Modular cleanrooms in action.
Understanding real world applications can provide insight into the benefits of modular cleanrooms. Here are examples of how companies leverage these systems:
Biotechnology laboratory expansion
Let’s say a biotechnology company needs additional space to support new research. They choose a modular cleanroom solution to build a controlled environment. Installation is completed in weeks, allowing research to begin sooner. The modular design allowed future expansion as research needs grow.
Electronics manufacturing facility
A hypothetical electronics manufacturer requires a Class 7 cleanroom for assembly. Modular cleanroom panels are installed within an existing plant without disrupting production. The company achieves compliance with industry standards and improves product yield.
Pharmaceutical packaging area
A pharmaceutical company expands its packaging operations. The modular cleanroom provides a compliant space quickly. With minimal downtime, the company increases throughput while maintaining quality.
Cost factors to consider.
Building a modular cleanroom involves various costs. Understanding these factors helps you budget accurately:
Size and classification
Higher standards require more advanced filtration and stricter environmental control. Larger cleanrooms and higher classifications generally cost more.
Materials and finishes
Quality of panels, flooring, and fixtures influences cost. Durable materials that meet your industry needs may be more expensive, but they deliver better performance.
HVAC and filtration systems
The complexity of HVAC and advanced filtration systems affects cost. Properly designed systems are essential for compliance.
Custom features
Special features such as controlled lighting, advanced monitoring systems, and connectivity add to costs. Evaluate needs carefully to balance your modular cleanroom’s performance and budget.
Installation services
Professional installation ensures your cleanroom performs as designed. Installation costs vary by location, complexity, and vendor.
The future of modular cleanrooms.
As industries innovate, the demand for flexible controlled spaces grows. Modular cleanrooms will continue to evolve with smart technologies and advanced materials. Prefabricated cleanrooms are becoming more integrated with digital monitoring and automation. This trend allows companies to achieve greater control and efficiency.
Furthermore, industries such as life sciences and advanced manufacturing are expanding globally. This expansion increases the need for rapid deployment of cleanroom systems. Modular cleanrooms offer the speed, scalability, and compliance that modern businesses require.
At the end of the day, building a modular cleanroom is a strategic investment for many industries.
Whether you need a space for critical research, high precision manufacturing, or regulated production, the right cleanroom system makes all the difference. Modular cleanrooms provide benefits such as speed, cost savings, flexibility, and compliance.
By planning thoroughly, selecting the right modular cleanroom manufacturers, and focusing on quality operations, you can build a cleanroom that meets your needs today and adapts tomorrow.
If you’re ready to explore modular cleanroom options, PodTech™ is here to help you navigate the process with expertise and proven solutions. Reach out to us to learn more about how we can support your cleanroom project.