Modular Clean Room

Modular Clean Room: The Complete Guide

Zonsteel modular clean room floor and top cover U channel, outside wall corner cover, inside corner cover, skirt board, and other two way or three way connection kit are made of aluminum. We have the full profiles fit for Zonsteel panels. We can also use stainless steel profiles.

Zonsteel modular clean room floor, if you don’t use local epoxy floor, we can offer PVC or raised floor.

To achieve 10-100,000 cleanliness class, we must purify air. In this case, Zonsteel primary filter, medium efficiency filter and high efficiency filter with duct can help. Alternatively, we may use FFU.

Zonsteel modular clean room can be flat packed and be install on site. Our professional installation team can do overseas work, the cost is round trip air tickets, board and lodging, and 100$ per day.

Delivery day of modular clean room is usually less than 15 days according to design and size.

Contact us today to customize your modular clean room!

 

Modular Clean Room: The complete FAQ Guide

 

Introduction

Welcome to our Frequently Asked Questions (FAQs) page. Here you will find answers to the most commonly asked questions about Modular Clean Rooms including applications, their role essential role in removing particles and preventing contamination from different production environments, design, hard wall and soft wall modular clean room types, air filters systems used to control air flow, customization options provided, etc.

If you have a question that isn’t answered here, please contact us.

 

What Is Modular Clean Room?

Figure 1  Modular Clean Room

Modular Clean Room is a controlled enclosed space used to protect different processing environments from contamination and form pollutants such as particulates, airborne organism, microbes, aerosol particles, dust, chemical vapors, etc. The controlled level of airborne particles/contaminants is kept within specified limits; it is also determined by the number of particles per cubic foot and particle size.

Modular clean room are essential for any application where small particles can adversely affect the production process for many industries such as pharmaceutical products, medical equipment, biotech, research centers, laboratories, aerospace, electronics, integrated circuits, LCD, micro LED displays and many more. Air filter systems including High-efficiency Particulate Air (HEPA) or Ultra-low Penetration Air  (ULPA) are the most commonly used to trap extremely smaller particulate contaminants, and protect the whole processes from harmful airborne.

Modular clean rooms are freestanding environments which are produced in compliance with ISO 14644-1:2015 standards, this ISO standard classify clean rooms from ISO 1 which is the “cleanest” class to ISO 9 being the “dirtiest” class but ensures a cleaner environment than a regular room.

Modular clean room systems are more preferred than conventional clean rooms, because they are highly versatile and configurable, they can be made from hard or soft walls panels. They come fully enclosed and fitted with doors, windows, wall system, ceiling system, transfer hatches and all necessary control parameters, equipment and accessories can be also provided.

 

What Are The Applications Of Modular Clean Rooms?

Figure 2  Modular Clean Room

Modular clean rooms are used in clean-critical processes for many industries where work flow, products and people cleanliness/decontamination are crucial to the success of the production. They are widely used in the following manufacturing and research facilities:

1. Pharmaceutical processing.
2. Biotech manufacturing.
3. Medical device manufacturing.
4. Vaccine manufacturing f
5. Aerospace industry.
6. Optical component manufacturing.
7. Automotive manufacturing.
8. Hospitals and c
9. Negative-pressure rooms.
10. Sterile c
11. Cannabis-related industry.
12. Microelectronics and nanotech industries.
13. Semiconductor manufacturing.
14. Food and beverage processing.
15. Cosmetics manufacturing.

 

What Are The Benefits Of Modular Clean Rooms?

Figure 3  Modular Clean Room

Modular clean rooms offer many distinct benefits when compared with conventionally constructed clean rooms:

High Performance

Modular clean room are mainly designed and engineered to respond to the most demanding application requirements, to ensure that, the latest technology air filter systems are used to provide the highest level of contamination protection, control of airborne particulates, air pressure, temperature, humidity, vibration, noise, etc.

Cost-effective

Unlike traditionally built clean rooms which are costly and take more time to be constructed, modular clean rooms can greatly reduce the construction time and costs as all components are delivered ready to make the assembly process simple and fast, while realizing important saving on costs of labors and materials. Furthermore, modular clean rooms feature an insulated wall system which acts as a thermal barrier and improve significantly the performance of the mechanical system; this can lower dramatically energy costs, while it maintains efficiently temperature levels.

Fast Installation

Modular clean rooms are much easier to assemble than conventional clean rooms because the aluminum structural framing and all components are factory pre-cut, mitered, welded, bolted, prewired and can be completely finished as per project requirements, this speed up the installation process and allow installation to be completed even in a single day.

Versatility

Despite the variety of applications and contamination protection needs for different industries, modular clean rooms can be virtually designed to ensure modular clean room systems are contaminant-free. Modular clean rooms can be engineered to meet any clean room ISO classification standards in terms of functional and aesthetics specifications, control parameters, mechanical performance, size, layout, configuration, finishes, equipment, accessories and more. A wide range of walls, ceilings and floors can be provided as per project requirement.

Fully Equipped

To ensure a safe and contamination free manufacturing process, modular clean rooms can be fully equipped as per the operational needs, a complete line of equipment can be integrated to modular clean room design including Airlocks, Air showers, Pass-through boxes, Workbenches, Laminar Flow Work Stations, Clean Room Light Fixtures, cabinets, etc.

Durability

High quality materials are used to ensure maximum durability for modular clean rooms, all elements are factory-produced and pre-engineered to ensure quality control, in addition to that, the highest strength aluminum framing and panels are used to provide robust walling, partitions, roofing and ceiling, while, the highest performance air filter systems and HAVC equipments are integrated to ensure maximum protection from any contamination.

Flexibility

Modular clean rooms are freestanding environments which are designed mainly to offer more flexibility than other traditional clean rooms. The whole unit can be installed quickly in few hours or days. Moreover, modular clean rooms come in temporary or permanent facilities and can be relocated, upgraded or expanded as needed. A wide range of structural framing, wall panels, materials and finishes can be also provided to suit virtually any environment.

 

Does Manufacturer Design Modular Clean Room?

Figure 4  Modular Clean Room

Yes, absolutely. Modular clean room can be designed to meet all functional and aesthetic requirements, a wide range of modular structures materials, framed walled system, aluminum, surface finishes, coating systems and equipments can be planned at a very early stage. Modular clean rooms are designed in compliance with the ISO 14644-1:2015 design standards, the latest Building Information Modeling technology (BIM) and precision engineering are used. Complete drawing concepts can be provided including 3D clean room drawings, detailed performance specifications, HVAC schematics and service layouts.

However, to ensure a successful design, many factors such as intended use, permissible particle concentration, production process, materials flow, number of employee, size, layout and budget fixed to build the facility should be considered in the planning phase.

Recirculating and non-recirculating modular clean rooms can be designed in a wide range of sizes, configurations and customization specifications.

 

What Are the ISO Classifications of Modular Clean Rooms?

Figure 5  Modular Clean Room

Modular clean rooms are classified according to the quantity and size of particles per cubic meters of air, while Modular clean rooms air cleanliness level is determined as per the standards of ISO 14644-1 and ISO 14698 which classify clean rooms from ISO 1 which is the “cleanest” class to ISO 9 being the “dirtiest” class but can ensure a cleaner environment than a regular room.

 

What Are The Requirements Of Modular Clean Rooms?

Figure 6  Modular Clean Room

To ensure the optimal performance of modular clean rooms critical factors such as Air flow design, frequency of air changes and exchange efficiency should be evaluated. Air changes per hour determine the number of times per hour the air in a modular clean room is replaced with filtered and treated clean air.

Clean rooms maintain particulate-free air through the use of either High-efficiency Particulate Air (HEPA) or Ultra-low Penetration Air (ULPA) filters that employ laminar or turbulent air flow systems which direct filtered air (in downward or in horizontal direction) in a constant stream towards filters located on walls near the clean room floor or through raised perforated floor panels.

Clean room level of air cleanliness is classified according to the number and size of particles permitted per volume of air in a specific amount of time. For example, an ISO 4 modular clean room will have 500 to 600 changes per hour, while an ISO 5 modular clean room will have 300 to 480 changes of air per hour. Modular clean room with high performance air flow will ensure all areas within a clean room will be covered by similar air changes during each hour; this will improve the overall air quality and will maintain a positive air pressure inside the modular clean room.

 

What Are The Types Of Modular Clean Room

Figure 7  Modular Clean Room

Modular clean rooms can be provided in different types including hard walls and soft walls:

Hard Wall Modular Clean Room

Hard wall modular clean rooms are rigid free-standing structures that are completely enclosed, their structural framing is made from aluminium, powder-coated steel or stainless steel, while, wall panels are available in sandwich panel, clear acrylic, static-dissipative PVC, polycarbonate and tempered glass, as well as opaque white polypropylene. All components of modular clean rooms are delivered ready for installation and can be bolted easily. Hard wall modular clean rooms are recommended for all applications, because their rigid walls system helps to reduce dirty air from entering the clean room and therefore, increase the volume of internal air pressure and provide a better performance than soft wall clean rooms.

Of course the hard wall modular clean room comes with air handling systems, to keep the indoor air in designed cleanliness.

Soft Wall Modular Clean Room

Softwalls modular clean rooms are the most economical type of clean rooms, but their usage is limited than other modular clean rooms made of rigid and hard walls, they are designed mainly to ensure a clean and protected environment against all particles, the positive airflow system works to pushes air down through the cleanroom to allows particles to be flushed out through the low level exhaust vent and offer a controlled environment free from contamination.

The soft walls are generally made from a clear plastic panel, PVC, Polysim, Vinyl curtains supported by steel tubing, aluminium, or stainless steel framing. In addition to their lightweight and relocation flexibility, softwall modular cleanrooms offers clear visibility due to its transparency and can be installed either as free-standing or suspended from the ceiling of a building. An adequate cleaning is required to ensure optimum performance.

 

What Sizes Are Modular Clean Rooms?

Figure 8  Modular Clean Room

Modular clean rooms can be designed to suit all project sizes; standard sizes are also available as follow:

Modular hard wall 2.4 m x 1.8 m x 2.4 m high

Modular hard wall 3 m x 6 m x 2.4 m high

Modular hard wall 3.6 m x 7.3 m x 2.4 m high

 

Modular soft wall 3.6 m x 1.8 m x 2.4 m high

Modular soft wall 1.8 m x 1.8 m x 2.4 m high

Modular soft wall 3.6 m x 6 m x 2.4 m high

You can ask for other size like 15m2, 30m2, 50m2, 100m2 etc.

 

How To Choose The Best Air Filter System For Modular Clean Room?

Figure 9  Modular Clean Room

Choosing a high-quality air filter system is vital to the functionality of any modular clean room as they are used to control airborne particulate levels and eliminate the spread of contaminants, pollen, mold, etc. Many factors should be considered prior to selecting the best system such as the level of effectiveness needed, the minimum number of air changes required per hour, number of people, production process, containment regulations and energy saving.

 

What Is The Difference and Similarities Between HEPA And ULPA Filters?

Figure 10  Modular Clean Room

ULPA and HEPA filters share many similarities in common but differ also in some characteristics, both of the filers are designed to prevent the spread of airborne bacteria in modular clean room, their system use diffusion, interception, and inertial impaction methods to trap and control contaminants, while both of the filters use layers of dense fibers to create a fine mesh filter that removes contaminants.

Both of the HEPA and ULPA filter systems can be used in various manufacturing applications that require a controlled environment free from any contamination such as laboratories, pharmaceutical; healthcare facility, surgical room, biotechnology, etc.

The most commonly used filter type is High-Efficiency Particulate Air (HEPA), this is due to its capabilities to filter particles of 0.3µm or larger, with an efficiency of 99.995%, but the HEPA filters do not filter out odor molecules and gasses. Whereas, Ultra Low Particulate Air (ULPA) filters are capable to remove 99.9995% of smaller contaminants larger than 0.1µm, ULPA filters are expensive filters but efficient.

 

What’s the Indoor Condition Type of Modular Clean Room?

 

There are three types.

Cleanliness Level 1-10000

The clean airflow of FFU continuously dilutes the internal air from top to bottom, and gradually discharges the internal pollution from the surrounding areas to achieve the cleanliness 1-10000. Different cleanliness levels mainly depend on the different air supply volume per unit time to achieve.

Temperature Control

For small area of modular clean room, ceiling small central air conditioning can be used to adjust the indoor temperature (generally controlled at 18-28 degrees) to meet the comfort of personnel. Meanwhile the modular clean room ceiling and wall use insulated sandwich panel to adding heat preservation function.

Temperature and Humidity Control

For the area requiring constant temperature and humidity in the production process, constant temperature and humidity air conditioning can be used to achieve, the temperature is controlled at 18-28 degrees, and the humidity is controlled at 50-70%. Also the modular clean room ceiling and wall use insulated sandwich panel to adding heat preservation function.

 

Does Manufacturer Provide Custom-made Modular Clean Rooms?

Figure 12  Modular Clean Room

There are several customization options that can be added to modular clean rooms to increase the control of contaminants and protect the production environment from harmful particulates. Customization includes the following:

Walls System

A variety of custom panel options can be offered to suit your functionality and aesthetics requirements as follow:

Softwall :  plastic, plastic laminate, vinyl, etc.

Hardwall : steel frame, aluminum frame, fiber-reinforced plastic (FRP), high-density polyethylene (HDPE), rockwool color steel sandwich panels, Polyurethane (PU) color steel sandwich panel, aluminum honeycomb sandwich panel and more.

Flooring Systems

The most durable modular clean room flooring can be applied including Perforated raised flooring, Seamless vinyl flooring, Epoxy floor paint on concrete, Rubber flooring, Heat sealed vinyl flooring system, Resinous floor system, Wear-resistant floor paint, etc.

Finishes

A complete selection of finishes that meet all modular clean rooms aesthetics and durability requirements can be applied including Melamine, Vinyl, PVC polyvinyl chloride; Fiberglass reinforced laminates, classic colors such as white and other RAL classic colors.

Lighting

A variety of energy efficient lighting which includes LED lights flush mounted on ceiling, light fixtures, switch and socket are also provided.

Equipment & Accessories

A complete line of equipment and accessories can be provided as per application requirements including Pass through Chambers, Air Locks, Air Showers, Gowning Room, etc.

A wide range of Ceilings, Roofing systems, Windows, Doors and more customization are available to customers in different material and design.

 

Are Modular Clean Rooms Compliant To International Building Code?

Figure 13  Modular Clean Room

Modular clean rooms are designed and engineered in accordance with the international Building codes in terms of health and safety regulations. Modular clean rooms are compliant to all the IBC performance related requirements, all components including structural framing, wall panels, air filters systems, HVAC system, etc. All materials and methods used are fully compatible with the International Electrical code, International Plumbing Code, the International Mechanical Code, Fire protection systems, etc.

 

Are Modular Clean Rooms Conformant With the International Standards?

Yes, in order to ensure high performance contamination protection, modular clean rooms are designed and engineered in compliance with the following international standards:

ISO 14644-1

The air cleanliness level of modular clean rooms is classified according to the ISO classification system ISO 14644-1 which determine the concentration of airborne particles in clean rooms per class and per particle size. This ISO standard classifies modular clean rooms by particle concentration; the cleanliness classes include ISO 1 (the “cleanest” class), ISO 2, ISO 3, ISO 4, ISO 5, ISO 6, ISO 7, ISO 8 and ISO 9 (the “dirtiest” class but cleaner than a regular room).

US FED STD 209E

The Federal Standard 209 (FS 209E) is equivalent to ISO classes 1/10/100/1000/10000/100000, this standard classifies air cleanliness based on the measurement of airborne particles. In 2001, the FS 209E standard has been replaced by ISO-14644-1, but it is still applicable.

USP Standards

This standard determine the safe handling of hazardous drugs and environmental protection, it applies to all hazardous drugs in healthcare environments and personnel. Modular clean rooms which are intended to be used for pharmaceutical products, shall respond to the USP 800, USP 795 and USP 797.

EU GMP guidelines

Modular clean rooms should meet the European Union Good Manufacturing Practices standards for medicines products manufacturing processes, handling, storage and packaging.

 

Are Modular Clean Rooms Energy Efficient?

Yes, absolutely. The newest technology design practices and cost-effective insulated sandwich panels are used to achieve maximum energy efficiency and ensure the highest levels of cleanliness. Furthermore, the International Energy Conservation Code  and Leadership in Energy and Environmental Design (LEED) standards are applied by setting performance requirements for the modular clean room HVAC system and electrical systems.

 

How Long Does It Take To Install Modular Clean Room?

Modular clean rooms are simple and fast to install, Hard Wall and Rigid Wall modular clean room can be installed in a single day, while, modular clean rooms made of Soft Wall can be installed in just a few hours. Modular clean rooms design ensures an easy assembly, because all of the structural framing and other components including wall panels and glazier are delivered ready for an easy installation, pre-wire wall panels can be provided as well for a quick connection, whereas the HVAC connections, lighting can be handled by a specialized engineer.

 

Do You Deliver Modular Clean Rooms Worldwide?

Yes, absolutely. We deliver Modular clean rooms internationally; we serve different locations in the World including the European Union, United Kingdom, the United States of America, Canada, Middle East, Gulf Countries, South America Countries etc. We offer our clients the most economic shipping rates, while a fast delivery can be made in 7 to 20 Days.

 

What Is The Average Cost Of Modular Clean Rooms?

The exact cost of modular clean room can be determined only after selecting the clean room requirements including the desired type, size, functional and aesthetic specifications, equipments, filters systems, customization options and other features. Most of modular clean room cost ranges from $2,000 per set to $20,000 per set.

 

What Covers The Warranty Of Modular Clean Rooms?

Modular clean rooms come with a standard product warranty of 1 year against any manufacturing defects, this warranty apply to all components and materials manufactured by  Zonsteel. Items which are not manufactured by us and integrated into our modular clean rooms are covered by the item’s original manufacturer warranty. Our support team will coordinate with the original manufacturer to ensure warranty terms are fulfilled.

 

Why Choose Zonsteel Modular Clean Rooms?

Since 2003, Zonesteel has been designing and manufacturing the most robust modular clean rooms that compete with the world’s largest manufacturers. Using our state of the art production facilities and our expertise, we can provide our clients with a one-stop solution for all of your clean rooms requirements including design, manufacturing, customization, equipment, accessories, turnkey service, and more. Our modular clean rooms can be designed to meet a diverse range of industries including life science, laboratories, pharmaceutical production, microelectronics, nanotech industries, etc. Our modular clean rooms are fully compliant to International Standard ISO 14644-1, USP, EU GMP guidelines and other containment regulations.

We specialize in designing and manufacturing the industry’s largest selection of modular clean room in different hard wall, rigid wall and soft wall systems at the most competitive price, the latest air treatment technology is integrated, in addition to the highest strength aluminum framing and the most durable materials such as free-standing walls, ceiling, partitions, HEPA/ULPA filtration, HVAC system, Air showers and Pass thrus, Lighting Systems/Fixtures and Flooring.

A variety of customization options ranging from steel, aluminum, stainless steel and fiberglass can be offered with our envelope systems, depending on your specific application or requirements. Our experienced team will support you from the initial design of your modular clean room to the final project delivery.

 

Interested In Our Modular Clean Rooms, Contact Us Now For A Free Quote?

To request a free quotation for your modular clean room project or for more detailed product information, contact us now.