How to choose the best pre-engineered cleanroom for your data center
If there’s one thing that’s guaranteed in our digital world of today, it’s the robust demand for servers and data centers, especially since the beginning of the generative AI era.
The leap has been in terms of not only quantity but also quality. Modern servers have made tremendous leaps in sophistication over the years. Today, they are more compact and powerful than they have ever been before.
But even with all the good they bring, they present some inevitable challenges, the most critical of which is the heat they generate. The hotter servers get, the more sophisticated cooling systems they need, the greater the need for sustainable, energy-efficient systems. Essentially, they must be housed in temperature-controlled environments to ensure their efficient operation.
That’s not all. Servers also have sensitive components that must be protected from dust and other contaminants. As such, anyone investing in a data center is essentially investing in a cleanroom – a controlled environment that must be equipped with systems for filtration, air conditioning, humidification, water leak detection, remote system monitoring, and beyond.
Setting up a stick-built cleanroom for your data center is a massive undertaking in terms of time, costs, labour, regulation, and more. So it’s unsurprising that more and more industry players are opting for pre-engineered or modular cleanrooms for data centers.
While pre-engineered cleanrooms offer many advantages over stick-built ones, not all pre-engineered cleanrooms are the same. The best pre-engineered cleanroom for data centers has many characteristics that set it apart from other modular cleanrooms. The best pre-engineered cleanroom for data centers takes into consideration industry best practices, regulatory requirements, individual business requirements, the local context, and many other factors.
In this set of blog posts, we’re going to discuss the features that the best pre-engineered cleanrooms for data centers have in common. From required ISO classifications and best practices to the cost of pre-engineered cleanrooms for data centers, we’ll cover it all.
What the best pre-engineered cleanrooms for data centers account for: Causes of data center contamination
Whether you use stick-built or modular cleanrooms for your data centers, there are some external and internal contaminants that you have to protect your equipment from.
External contaminants include airborne pollutants like particulate matter, pollen, construction dust, and even sea salt. When personnel or visitors enter the facility, they may also contaminate the space with skin particles, shedding hair, and fibres or lint from clothing.
In the internal environment of the data center cleanroom, emissions from floor tiles, furniture, packaging material, and corrosive gases emitted during processes also pose a threat to the safety and longevity of the equipment.
Off-site fabrication, combined with the absence of bricks and cement used in traditional construction, means that modular cleanrooms for data centers don’t present all the contamination threats that stick-built cleanrooms have. Contamination from concrete dust (which often comprises calcium, silica, and other corrosive and abrasive by-products) is minimised in modular cleanrooms.
Nonetheless, some other contaminants pose threats even for pre-engineered data centers. The best pre-engineered cleanroom for data centers will protect the equipment inside from ferrous metal particles, corrosive gases, zinc and tin whiskers, chlorides, and electrostatic dust.
Ferrous metal particles are released by numerous components of the cleanroom itself, including new floor tiles, worn-out parts in HVAC units, tape drives, printers, conduit pipes, and other mechanical components. The ferrous particles must be eliminated because the metallic nature of these contaminants can cause electrical damage to circuit boards.
Gases like hydrogen sulphide, sulphur dioxide, nitrogen dioxide, ozone, chlorine, and the like must also be eliminated from the cleanroom because they cause silver and copper to corrode. This means that the presence of these contaminants can damage wiring and delicate metallic parts in circuit boards and chips.
Zinc and tin whiskers are the small metal filaments that escape from electroplated steel floor plates, ceiling bars, and other metal components used in the construction of modular cleanrooms for data centers. As efficient conductors of electricity, they present similar threats as other metallic components.
Chlorides and other salts in the air pose the threat of corroding metals, especially in coastal areas. Meanwhile, dust and lint from any surface, be it paper, cardboard or clothing, can become static-charged. This electrostatic dust can interfere with the working of servers, causing erroneous commands, resets, data losses, and other issues.
As you embark on your expedition of finding the best pre-engineered cleanroom for your data centers, make sure that anyone you choose is designed to prevent contamination with the above gases and particles. If you don’t have well-designed modular cleanrooms for your data centers, you run the risk of various problems. Think equipment failure, a lack of power efficiency, head crashes, and contact intermittence, none of which you want if you want to run an efficient, successful data center.
Best practices for the best pre-engineered cleanroom for data centers
As a data center operator, there are some best practices you can adopt to ensure that your modular cleanroom operates at its highest possible efficiency.
To maintain the optimal environment for your equipment, you must monitor humidity levels and atmospheric corrosion. The American Society of Heating, Refrigerating, and Air-Conditioning Engineers (ASHRAE) recommends that you monitor copper and silver reactivity, i.e. corrosion, limiting it to 300 Å or less. You must restrict foot traffic and use sticky mats. Maintenance of your modular cleanroom for your data center also involves using chemical filtration systems and replacing dust filters regularly.
Additionally, you must conduct annual contamination assessments and carry out deep cleaning to ensure that you continue to maintain required standards. You can contract third parties for both testing and cleaning; we recommend employing a company or service that is familiar with the standards required by your cleanroom.
But adopting these best practices isn’t enough. Before you even have a modular cleanroom for your data center up and running, you have to make the important decision of choosing which cleanroom type and which cleanroom manufacturer you want to work with. You have to think about design, engineering and ISO classifications as well as plan for expansion, redundancy, maintenance, and longevity.
Setting up the best pre-engineered cleanroom for data centers is a complex multi-step process that requires that you partner up with the right engineering company. In part 2 of this blog post, we’re going to explore what makes a successful cleanroom project in the IT industry, which ISO standards you need to meet, the specifications you need to assess, and the type of engineering team you should partner with.
In this blog post, we’re concerned with finding the best pre-engineered cleanroom for data centers. But whether you’re in pharmaceuticals, semiconductors, academic research, defence, or any other industry that calls for the use of a controlled environment, there are certain specifications you must understand to make a well-considered decision. Understanding the intricacies of not only cleanroom design and construction materials but also costs and compliance is crucial to ensuring the success of your cleanroom project.
Factors to consider when identifying the best pre-engineered cleanroom for data centers
You can only find the best pre-engineered cleanroom for data centers if you understand and take into consideration the following critical factors:
Cleanroom classifications. When it comes to ISO classifications, there are two important aspects to getting compliance right. First, you must select the ISO class appropriate to your particular application. Second, you must meet all the specifications detailed in the classification: this includes not only permissible contaminant levels but also other design, environmental and operational parameters. Compliance with these ISO standards is not a one-and-done affair; it is an ongoing process that requires continued commitment to the process and regular assessments.
HVAC systems. Given the strict contamination control required in modular cleanrooms for data centers, having a robust, advanced HVAC system is non-negotiable. Your HVAC unit must make use of HEPA or ULPA filters. It should also provide efficient control over temperature, humidity, air quality, and other environmental factors within your controlled space.
Cleanroom design. Whether you’re looking into modular cleanrooms for data centers or for any other application, your design must prioritise contamination control, airflow management, and efficient workflows. This involves paying close attention to elements like air filtration systems, room layout, personnel movement, and material movement.
Project management. An often overlooked part of the process, project management can make all the difference between a success story and a failure. A skilled and experienced project manager or management team is key to ensuring that the project is completed as per your specifications, on schedule, and within budget. This is particularly important when it comes to modular cleanrooms for your data center because, in modular systems, since so many elements – like utility distribution, lighting, waste management systems, HVAC, etc. – are integrated, your project manager should have a good understanding and a bird’s eye view of the entire process, not just the design or construction parts.
A step-by-step guide to choosing the best pre-engineered cleanroom for your data center
Now that you know the basics of what goes into assessing a modular cleanroom for a data center, let’s go step-by-step, understanding the items you need to check off your list as you embark on this process:
Step 1: Familiarise yourself with your industry requirements. Depending on the industry you’re in and the process you’re carrying out, the standards and regulations for your cleanrooms will vary. For instance, biotech industries call for stringent contamination control to ensure the safety and efficacy of the products manufactured. The cleanroom must meet standards set by regulatory bodies like not only the ISO but also the FDA, EMA, or other relevant local or regional authority. Similarly, in robotics, medical devices, aerospace, semiconductors, and electronics, there are different regulations and requirements.
When it comes to data centers, your facility should be designed to protect IT equipment and prevent unnecessary downtime. Modular cleanrooms for data centers must meet the ISO class 8 standard (more on this below).
Step 2: Deeply understand the ISO cleanroom classifications. Developed by the International Organisation for Standardisation (ISO), the ISO 14644-1 standard outlines the specifications for cleanroom classifications ranging from ISO 1 to ISO 9. The ISO standard of any cleanroom is determined by the number and size of particles permitted per cubic metre of air in the cleanroom. ISO 1 is the strictest cleanroom classification, while ISO 9 is the least strict.
As we mentioned earlier, modular cleanrooms for data centers must comply with ISO class 8. Meeting these standards requires that data centers undergo a particle count test, airflow test, and air pressure difference test every year.
These tests should yield particle counts as follows: a maximum allowable concentration of 3,520,000 particles per cubic metre of a size of at least 0.5 micrometres in diameter; 8,320,000 particles per cubic metre for 1 micrometre particles; and 29,333 particles per cubic metre for 5 micrometre particles. ISO class 8 cleanrooms must also maintain an average air change rate of 5 to 48 changes per hour and an average airflow velocity of 1 to 8 feet per minute.
Step 3: Assess the cleanroom size and layout. The size and layout of the best pre-engineered cleanroom for your data center will depend on the equipment you need to house, the nature of your operations, the number of personnel at the facility, and other details specific to your project. Make sure you account for people, machines, and product flow as you determine the right size for your modular facility. Also consider if you may need dedicated spaces for material transfer, sterilisation, and any other protocols specific to your cleanroom standards.
Step 4: Evaluate the construction materials. In part 1, we saw how contamination threats to the cleanroom come not only from outside but also inside the space itself. This is why, when selecting the best pre-engineered cleanroom for your data center, you should ensure that the walls and ceilings are made of materials like HDRE, FRP, and aluminium since they resist particle build-up and are smooth and easy to clean. The floors should be made of non-porous material like vinyl or should be epoxy-coated. Additionally, doors and windows in the cleanroom should be secure and able to withstand the pressure levels maintained inside. All the materials chosen should be compatible with the disinfectants and cleaning agents used in the industry.
Step 5: Address your air filtration and HVAC needs. Heating, ventilation, and air conditioning (HVAC) is arguably one of the most important components of your cleanroom, regardless of application. Your HVAC unit is responsible for controlling temperature, humidity, airflow, and several other environmental parameters, including contamination levels. It’s also critical to ensure compliance with the appropriate ISO level.
The best pre-engineered cleanroom for your data centers uses an HVAC system with HEPA (high-efficiency particulate matter) and/or ULPA (ultra-low penetration air) filters to remove 99.9% of particles that are 0.3 microns and 0.12 microns in size or larger, respectively. These filters must be periodically maintained and/or replaced to ensure that your HVAC continues to operate as intended.
Step 6. Identify and put in place the required cleanroom protocols. Beyond the design of a cleanroom, many other factors make it suitable or unsuitable for use in a data center. Standard operating procedures, including required cleanroom protocols, maintain suitability over time for a modular cleanroom to be used in a data center or any other facility.
These protocols may also determine whether you need special spaces allocated to them in the cleanroom. Think special contained areas for gowning and handwashing. You may need to predetermine how material transfer will happen in the facility: how will materials enter and exit the facility without contaminating the space? Your answers to these questions may lead you to installing pass-through chambers, airlocks, or specialised containers so that these processes can be carried out.
Step 7: Optimising for sustainability and energy efficiency. Because of the constant need to monitor and control the internal environment, modular cleanrooms for data centers can be extremely energy-intensive installations. So the best pre-engineered cleanrooms for data centers almost always find ways to improve the energy efficiency of the facility. These interventions should reduce the operational costs of your facility without compromising on compliance with industry requirements.
The best pre-engineered cleanrooms for data centers use LED lighting, variable airflow systems, and recyclable and reusable materials to reduce the total carbon footprint of the facility.
Why pre-engineered cleanrooms are the best way forward for data centers
Regardless of its application, a pre-engineered cleanroom almost always turns out to be more cost-effective than its stick-built counterparts.
From streamlined manufacturing and lower labour costs to shorter installation timelines and scope for expansion and reconfiguration, pre-engineered modular cleanrooms offer unparalleled benefits. When it comes to cleanrooms for data centers, modularity and the energy efficiency it brings offer even greater benefits.
The pre-engineered cleanroom for data centers cost will vary depending on its size, complexity, construction materials, HVAC system sophistication, and numerous other factors. But the most important factor determining success is your choice of engineering partner.
Do they have the expertise and experience you need? Do they offer comprehensive, end-to-end services? What is their track record with compliance in your country? And how are their project management skills?
We at PodTech™ pride ourselves on our global experience, rigour with compliance, and expertise in project management. If you’re looking for a partner to kick off a cleanroom project, look no further. Get in touch to discover how we can solve for you.