Axenic System is one of the leading company engaged in architectural
designing, planning, installation, commissioning of HVAC and Turnkey
construction for cleanroom projects
Modular Cleanrooms
Table of Contents
Introduction to Modular Cleanrooms
AXENIC SYSTEMS (established in 1995) is one of the leading companies engaged in planning and installing of Modular Cleanrooms to carry out several manufacturing processes. Modular Cleanroom is constructed using pre-fabricated, manufactured components that are assembled according to provisions on-site. A team of highly skilled professionals plans systematic stages to ensure the finished product for various applications such as automotive, aerospace, pharmaceuticals and electronics.
Modular design is a method to design that separates a system into compact, self-contained units that can be made independently then combined in several ways to create a whole system. In terms of building and architecture, modular design integrates universal components that are manufactured in a factory, then assembled on-site into anticipated configuration.
Modular Cleanrooms is a cleanroom that is constructed from pre-fabricated, manufactured components that are assembled according to specifications on-site. These prefab components contain wall and ceiling panels as well as distinctive features like pass thru chamber panels and air locks.
There are several different design options for modular cleanrooms, depending on the cleanroom’s needs in terms of application and required classification. They can be free-standing structures or incorporate existing walls and structures within your facility or factory. Modular cleanrooms incorporate existing equipment and HVAC. They can have hard walls that resemble traditional construction or soft walls that are slightly tent-like for better flexibility and ease of transport.
Modular Clean room designs
The nature and design of the cleanroom is mainly dependent on the production necessities and the standards that need to be met and maintained. The Modular cleanroom design and specification of mechanisms, surface finish and materials is done at a very initial stage and can be done in consultation. The construction of Modular cleanroom comprises the manufacture, assembly and commissioning of these components in accordance with the detailed design.
Modular cleanroom designs are divided into different categories and they include:
MonoBlock System: The mono-block system can be prepared from two metal facing wall or ceiling sheets that are machined to tight tolerances and then are powder coated and treated according to the cleanroom design requests. These kinds of cleanroom walls are commonly used for pharmaceutical cleanrooms, heavy duty construction and generally for fixed layouts of several rooms.
The advantage of mono-block systems includes:
- Mono Block Systems are used in high-end cleanrooms.
- Manufactured from solid structures.
- Comprises insulation characteristics.
- Provided with smooth surfaces and have flush joints
Modular wall system: Modular wall system is a single shell or double shell framed walled system. Modular structures made from aluminium glassware or various other types of panel are commonly perfect for applications in semiconductors. The key advantage of modular cleanrooms is that they can easily be adjusted to any layout or change in production requirements.
The advantages of the modular systems include:
- The production cost is comparatively low.
- Modular wall system is used in high cleanroom classes.
- They are flexible and thus, easy to change according to construction requirements.
- Horizontal pipes can be combined into the panel.
Benefits
- Modular cleanroom can be built fast and quickly with minimal interruption in your facility.
- They can be easily extended or modified.
- Modular cleanrooms can be taken apart and reassembled in a new location.
- Even though the mechanisms of modular cleanrooms are somewhat universal, it can still be customized with a wide range of special features and equipment to make sure that it meets the application’s particular needs.
- Modular cleanrooms save time and money over most conventionally constructed cleanrooms.
Types of Modular Clean Rooms
There are 2 types of Modular cleanroom:
- Modular HardWall Cleanrooms
- Modular Softwall Cleanrooms
Modular HardWall Cleanrooms:
Modular HardWall Cleanrooms have solid wall panels made from a variety of materials. Unlike softwall clean rooms, these rooms are reinforced by their walls and not a frame, which contains a ceiling grid and roof. Modular HardWall Cleanrooms carefully resemble permanent clean rooms except that their components can be simply replaced.
The design of Modular HardWall Cleanrooms offers an additional layer of protection for the completion of testing and research. They keep a zone safe and out of the reach of airborne contaminants. They are generally used when accurate control of temperature and humidity are a necessity. Modular HardWall Cleanrooms deliver resistance to impact, are easy to clean, offer excellent lighting, and allow external staff to supervise processes.
Modular Softwall Cleanrooms:
Modular Softwall Cleanrooms have soft flexible walls and are compact in size than traditional hard wall clean rooms. They are a cost effective solution when size and flexibility are a necessity. In some conditions, it is essential to add an extra layer of isolation inside a hard wall clean room. In those situations, Modular Softwall Cleanrooms are perfect since they can instantly be placed and put to use.
There are several terms used to define Modular Softwall Cleanrooms, which include portable, prefabricated and tent like. All Modular Softwall Cleanrooms have the same properties, which are economical, easy to install, and can be readily expanded. Modular Softwall Cleanrooms are built through the use of a metal frame and see-through panels or curtains have HEPA filters, ceiling lights. Air is pushed down through the Modular Softwall Cleanrooms, pushing out undesirable particles and protecting sensitive instruments and procedures.
Construction
The procedure of constructing a Modular cleanroom initiates with the selection of the components, which contains the materials for the walls, frame, ceiling, floor, and air filtration system. The base for the selection procedure depends on the anticipated classification. In order for a clean room to have a higher classification, it has to be manufactured using high quality resources and components.
The primary consideration while choosing the nature of a clean room depends on the types of walls, which can be fabric or solid. Each type, fabric or solid, comes in several varieties that can be custom fit to meet the requirements of the manufacturing procedure or testing needs.
Some major points considered for cleanroom construction:
Risk and Schedule Management: –
Our leading project control team takes a pre-emptive approach throughout the project life cycle in considering schedules and risks – key factors in the success of any project. As the construction manager and prime, we assess all of our trade partner sub-contractors against our safety, capability, and financial strength standards.
Sub-contractor Supervision: –
We have solid relationships with local subcontractor communities throughout the globe. We build a proposal list of local trade contractors who are familiar with the location, region, and project type from our proprietary contractor database.
Resources Management: –
Our procurement experts enhance supply chain procedures to ensure the most cost-effective development, obtaining, purchasing, moving, storing and controlling of materials. We have enthusiastic expertise in logistics as well as expertise in obtaining owner equipment, trade and professional services and materials in addition to subcontracts for construction.
Installation
The installation and construction of Modular Cleanrooms includes: –
Custom Modular Cleanroom Designs
- Class 100 to 100k / ISO5 to ISO8 per ISO 1 4664-1 and FDA STD 209E
- One pass or recirculating
- Temperature/Humidity environmental controls
- Standard modular or ACS seamless pharmaceutical modular wall system
- Custom floor plans
- Custom Height
- Equipment mezzanines
- Drawings and engineering
Huge Modular Material Options
- Wall surfaces: Melamine, vinyl coated gypsum, FRP, glass, polycarbonate, painted aluminium, or stainless steel
- Wall core: honeycomb, urethane, polystyrene, or aluminium honeycomb
- Doors: single, double, automatic sliding, motorized roll up, interlock systems
- Flooring: VCT, heat welded vinyl, epoxy, anti-static, and raised
- Lighting: T-8, LED, tear drop, skylight tubes
Modular Cleanrooms Equipment Options
- HEPA and ULPA fan filter units, standard and RSR
- ACS2000 power saver, ACS3000 room monitoring system: T/RH/Air pressure
- Air showers, pass-thrus
Applications
Some industries that uses modular cleanrooms are: –
Aerospace: The critical nature of equipment manufactured for aerospace requires that components produced are free from dangers of contaminants and particulates. This can only be accomplished in a Modular cleanroom. The slightest fault or weakness in a delicate instrument can result in dangerous conditions and substantial losses.
Automotive: The automobile industry makes extensive use of Modular cleanroom from the beginning procedure to the final product. In the early design phase, prototypes are tested and examined in clean rooms to establish their sustainability.
Pharmaceutical: The challenging regulations and health standards for the production of drugs and medicines has made the Pharmaceutical industry a prime user of Modular cleanroom. The industry has a constant concern for any form of bacterial contamination and takes extreme measures to make sure every product is antiseptic and clean of any possible side effects from production errors.
Electronics: Modular cleanrooms for the electronics industry are inexpensive and more flexible than traditional clean rooms. The design of Modular cleanroom permits for expansion and modification of the clean room depending on the necessities of production. For the electronics industry, Modular cleanrooms ensure the stability and presentation of their products by producing them in contaminant free surroundings. The manufacturing space must be very clean and vibrant.
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