What materials are used in modular clean rooms?

What Materials Are Used in Modular Clean Rooms?

• Wall Panels

The wall panels of modular clean rooms are typically made from non-porous materials such as aluminum, stainless steel, or high-density polyethylene (HDPE). Aluminum panels are lightweight, durable, and easily cleaned, while stainless steel offers excellent resistance to corrosion and is also easy to sanitize. HDPE is often used for its chemical resistance and lower cost. According to ISO 14644, the surfaces must be smooth to minimize particulate retention.

• Flooring Materials

Clean room flooring is another critical component. It must be durable, easy to clean, and resistant to chemicals. Common materials include epoxy resin and vinyl. Epoxy flooring can withstand heavy foot traffic and chemical spills, with a thickness of around 3 to 5 mm. Vinyl flooring offers a seamless finish, minimizing dust accumulation, and can be installed with a thickness of approximately 2 mm to provide an effective barrier against contaminants.

• Ceiling Systems

Ceiling systems in modular clean rooms are designed to support air filtration and lighting while maintaining a clean environment. Materials like mineral fiber tiles or aluminum are commonly used, as they are lightweight and easy to clean. The ceiling should comply with ISO standards, which dictate the allowable particulate levels in the air. For instance, ISO5 requires no more than 3,520 particles per cubic meter of air.

• Filtration Systems

Air filtration is a critical aspect of clean room design. HEPA (High-Efficiency Particulate Air) filters are standard, capturing 99.97% of particles as small as 0.3 microns. ULPA (Ultra-Low Penetration Air) filters are also used for more stringent Clean Room Classifications. The use of these filters helps maintain the required cleanliness levels in accordance with iso 14644-1, which specifies the maximum allowable particle concentration in clean rooms.

• Gasketing and Seals

Proper gasketing and sealing materials are essential for maintaining clean room integrity. Materials such as silicone or rubber gaskets are commonly used to ensure airtight seals between walls, ceilings, and floors. These materials prevent air leaks that could compromise positive pressure and contamination control. According to ISO 14644-3, maintaining a controlled environment is crucial for achieving compliance

• Windows and Doors

Windows in clean rooms are typically made from tempered glass or polycarbonate to provide visibility while maintaining a sterile environment. Doors are often designed as double-door systems with airlocks to prevent contamination. These elements help maintain the positive pressure necessary in ISO5 environments or higher.

• HVAC Systems

Heating, ventilation, and air conditioning (HVAC) systems in modular clean rooms are engineered to provide controlled airflow and temperature. High-Efficiency Particulate Air (HEPA) filters are standard, capable of capturing 99.97% of particles as small as 0.3 microns. This filtration is crucial for maintaining the air quality required by ISO6 or cleaner environments.

• ISO 14644-1:Specifies the classification of air cleanliness.

• ISO 14644-4:Details the design and construction of clean rooms.

• iso 14644-5:Focuses on operation and monitoring.

• FS209E:A legacy standard that classifies clean room environments.

Make a Clean Room

Choose the Location

Selecting an appropriate location is crucial for a modular  clean room. Ideal sites are away from high-traffic areas, with controlled access to reduce contamination risks. Proximity to utilities and support services is also essential for efficiency.

Design the Layout

The layout of a clean room should facilitate workflow while maintaining cleanliness. This includes planning for gowns, equipment, and material flow. Proper zoning helps prevent cross-contamination and ensures a streamlined process.

Select Construction Materials

Construction materials should be non-porous, easy to clean, and resistant to chemicals. Common materials include stainless steel, epoxy flooring, and specialized clean room panels. These materials help maintain the necessary cleanliness standards.

Implement Monitoring Systems

Monitoring systems are essential for maintaining clean room standards. They track temperature, humidity, and particulate levels, ensuring compliance with regulations. Regular audits and maintenance help address potential contamination issues promptly.

What Are Cleanroom walls Made Of?

• Stainless Steel Panels

Cleanroom walls are often made from stainless steel due to its durability and resistance to corrosion. This material is easy to clean, ensuring that surfaces remain free from contaminants.

• Aluminum Composite Panels

Aluminum composite panels are lightweight and offer good insulation properties. These panels are also non-porous, making them suitable for cleanroom environments where cleanliness is paramount.

• Vinyl Coated Gypsum

Vinyl coated gypsum is another popular choice for cleanroom walls. It combines durability with ease of maintenance and provides a smooth surface that minimizes dust accumulation.

• High-Density Polyethylene (HDPE)

High-density polyethylene is used for its chemical resistance and impact durability. HDPE panels are easy to install and maintain, making them an effective choice for cleanroom construction.

• Glass Walls

Glass walls are increasingly used in cleanrooms for visibility and aesthetics. Typically made from tempered or laminated glass, they offer a smooth, non-porous surface that is easy to clean and maintain.

• Insulated Wall Systems

Insulated wall systems incorporate layers of material to enhance thermal and acoustic performance. These walls help maintain temperature control and reduce noise, which is beneficial in sensitive cleanroom environments.

• Integrated Services Panels

Some cleanroom walls include integrated services panels for electrical and HVAC systems. These panels minimize disruptions to the cleanroom environment while providing necessary utilities efficiently.

Why Is Steel Used in Modular Construction?

1. Structural Strength

Steel is renowned for its high strength-to-weight ratio, making it ideal for modular construction. It provides robust support for multi-story buildings while minimizing the overall weight of the structure.

2. Durability and Longevity

Steel is highly durable and resistant to various environmental factors, including corrosion and pests. This longevity reduces the need for frequent repairs and replacements, leading to lower life-cycle costs.

3. Quick Assembly

Modular components made of steel can be prefabricated off-site, allowing for quick assembly on-site. This efficiency not only speeds up construction timelines but also minimizes disruption to the surrounding area.

4. Sustainability

Using steel in construction contributes to sustainability efforts. Steel is recyclable, and its production can be optimized to reduce energy consumption, making it a more environmentally friendly choice compared to other materials.

What Are Cleanroom Garments Made Of?

1. Non-Woven Fabrics: Cleanroom garments are commonly made from non-woven fabrics, which provide excellent barrier protection against particles. These materials are lightweight, breathable, and help maintain comfort during extended wear.

2. Polyester and Polypropylene: Polyester and polypropylene are synthetic fibers frequently used in cleanroom apparel. They are resistant to chemicals and provide a good balance of durability and comfort, essential for cleanroom environments.

3. Static-Control Fabrics: Static-control fabrics are crucial in cleanrooms to prevent electrostatic discharge (ESD). These garments are designed to dissipate static electricity, protecting sensitive electronic components during manufacturing.

4. Breathable Membranes: Breathable membranes in cleanroom garments allow moisture to escape while blocking contaminants. This feature enhances comfort and reduces the risk of sweat accumulation, which can lead to contamination during sensitive processes.

The Standards for ISO 8 Clean Rooms

• Air Change Rate

The air change rate for ISO 8 Clean rooms typically requires a minimum of 20 air changes per hour. This ensures that contaminants are effectively removed and replaced with filtered air, maintaining the room's cleanliness.

• Maintenance Protocols

Routine maintenance of cleanroom facilities and equipment is critical under ISO 8 standards. Regular cleaning schedules and equipment checks help sustain the cleanroom's integrity and prevent potential contamination issues.

• Validation Processes

Validation of cleanroom environments is essential to ensure compliance with ISO 8 standards. This includes periodic testing of air quality, particle counts, and airflow patterns to confirm that the cleanroom meets established cleanliness criteria.

• Cleanroom design Requirements

The design of ISO 8 Clean rooms must facilitate easy cleaning and maintenance. Smooth, non-porous surfaces, rounded corners, and appropriate airlock systems are crucial to minimize dust accumulation and contamination risk.

• Access Control Measures

Access control is vital in ISO 8 clean rooms to limit the number of personnel entering. Airlocks and gowning rooms help maintain cleanliness by ensuring that only properly attired individuals enter the controlled environment.

• Equipment Standards

All equipment used in ISO 8 clean rooms should be designed for easy cleaning and disinfection. Equipment must also comply with contamination control measures, ensuring that it does not introduce particles into the cleanroom environment.