Cleanroom Facilities
Digital Air Control is builder of cleanroom and laboratory facilities. Our staff has been involved in numerous cleanroom facilities over the years. Our team members have over 40 years for cleanroom design-build experience in some of the most technologically advanced facilites in the world.
Our team members have designed and installed cleanrooms facilities all around the world. We can take your baseline parameters for your facility and work with you to develop the baseline requirements for your facility.
Digital Air Control has always been a design builder of our projects. Design-build delivery formats are best suited for our team members and abilities. With new additions in staff, we are building up our cleanroom and laboratory design build experience.
We welcome the opportunity to assist you with providing a turnkey scope of work and pricing for your project. We are specialists in design build delivery methods. Digital Air Control has cleanroom designers, cleanroom project managers, cleanroom field staff with over 40 years of experience in design build cleanroom construction. Our staff has built cleanrooms in numerous sectors from Nanotechnology, Pharmaceutical, Biotechnology, Medical Device, Energy, Government, Microelectronic, Flat Panel Display, MEMS Device, Cleanroom Laundries, Telecommunications, Metrological, Coatings, and University.
Digital Air Control's staff has handled all aspects of cleanroom facilities from ground up building construction to final fit up of the cleanroom equipment. Our staff has designed and built all divisions of construction from 100 square foot to 300,000 square foot. Digital Air Control will provide a fixed price or guaranteed maximum price for your cleanroom facility.
Cleanroom Facilities: Articles
Cleanroom Projects…
Cleanroom Projects…
Bill Johnson (Cleanroom Facilities) 2012-03-05 22:28:15
Our Staff at Digital Air Control has extensive experience in cleanroom projects. Our team received their experience while working at Lepco and Luwa. Our cleanroom team is made of project managers, technical sales people, project designers, construction superintendents, operations managers, quality control experts, and safety supervisors. Below is the list of projects our ceanroom team has been involved in:
3M Corporation Product Development Rochester, New York Environmental Abaxis Analysis Equipment Sunnyvale, California Environmental Abbott Labs/Methodist Hospital Pharmaceuticals Houston, Texas Class 10,000 Advanced Micro Devices, Inc. Integrated Circuit Assembly San Antonio, Texas Class 100 Advanced Micro Devices, Inc. Test/Inspection Austin, Texas Class 10/1000 Advanced Micro Devices, Inc. Product Development San Antonio, Texas Class 10/100 Advanced Neuromodulation Systems Neuromodulation Products Allen, Texas Class 10,000/100,000 Advanced Vascular Technologies Medical Implant Production Webster, Texas Class 10,000 Agere Systems CMP Remodel Orlando, Florida Class 1/10 AGI Dermatics Pharmaceuticals Freeport, New York Class 1000 Air Products & Chemicals Gas Cabinet Manifolds Allentown, Pennsylvania Class 10/100 Alcon Laboratories Pharmaceuticals Dallas, Texas Class 1000 Allergan, Inc. Pharmaceuticals Waco, Texas Class 100/1000 Allied Signal, Inc. Government - Defense Kansas City, Missouri Class 1000/10,000 Amkor/Anam Assembly & Test Facility Sta. Rosa, Laguna, Philippines Class 10,000 AMP/Carroll Touch Component Packaging Round Rock, Texas Class 100,000 Apex Lithography Humidity Controlled Printing Austin, Texas & Lithography Plant Maintenance A Plus International Cleanroom Laundry Suzhou, China Class 10/100/1,000 Applied Materials Development of Semiconductor Santa Clara, California Production Equipment Class 10 Applied Materials Research & Development San Jose, California Class 10 AP Technoglass Product Development Sidney, Ohio Class 100,000 Ardex, Inc. Product Development Austin, Texas Class 1000 Ashland Chemical Application Lab Dublin, Ohio Class 10/100/1000 Asyst Technologies SMIF Technology Milpitas, California Class 1/1000 A T & T Dry Film - Etch Lab Richmond, Virginia Class 10,000 A T & T Pipe Fab Orlando, Florida Class 1,000 ATS South Semiconductor Packaging Dallas, Texas Class 1,000 Barrios Technologies, Inc. Instrument Cleaning & Calibration Houston, Texas Class 100/1000 Bayer Corporation Pharmaceuticals Clayton, South Carolina Class 100/1000 Biotech, Resources, Inc. Biomedical Research San Antonio, Texas Class 10 BOC Edwards/Kachina Wafer Fab Phoenix, Arizona Class 100/1000 Boehringer Weighting Stations Indianapolis, Indiana Class 100 Brice Building Company, Inc. Mineral Research Birmingham, Alabama Class 100/1,000 Brooks AFB Ground-Up Oxygen Chamber San Antonio, Texas Class 10,000 Bunker Plastics Plastic/Glass Coating Grand Saline, Texas Class 100 Cardiovascular Systems Medical-Blood Filtration The Woodlands, Texas Class 10,000 Cardiovascular Systems Medical-Blood Filtration The Woodlands, Texas Class 100,000 Chemtrace Trace Metal Analysis Hayward, California Class 1000 Choate/PDC Sterile Manufacturing Charleston, South Carolina Class 10,000/100,000 Cirent Semiconductor Chemical Machine Polishing Orlando, Florida Class 1/10 Clemson University Material Research Anderson, South Carolina Class 100 – ISO Class 5 Codeon Chip Processing Columbia, Maryland Class 10,000/100,000 Compaq Computer Corporation Electronic Assembly Houston, Texas Class 100 Compaq Computer Corporation R & D Manufacturing Houston, Texas Class 10,000/100,000 Compuworld, S.A. de C.V. Disk Drive Assembly Guadalajara, Jalisco, Mexico Class 100/1000 Compugraphics USA Photomask Los Gatos, California Class 100 Covance Pharmaceuticals Pharmaceuticals Raleigh, North Carolina Class 1000/10,000 Cray Research, Inc. Computer Assembly Colorado Springs, Colorado Class 1000 Cree Research Research and Development Durham, North Carolina Class 10,000 CTS Corporation Wireless Components Chicago, Illinois Class 100/1000 Cummins Engine Metrology Columbus, Indiana Class 1000 Cypress Semiconductor Wafer Assembly Austin, Texas Class 10 DNS Electronics Equipment Manufacturing Training Sunnyvale, California Class 100 Data Medical Association Development of Blood Arlington, Texas Chemical Reagents Class 1000 Diamonex, Inc. Optical Coating Allentown, Pennsylvania Class 100 Digital Audio Disc Corporation Product Development Terre Haute, Indiana Class 100 Digital Optics Optics Charlotte, North Carolina Class 1000 Dow Chemical Analytical Group High Purity Chemical Production Freeport, Texas Class 100 Dow Chemical Co., Texas Oper. Polycarbonate Packaging Freeport, Texas Class 10,000 Dow Chemical Co., Texas Oper. Polycarbonate Processing Freeport, Texas Class 10,000 Dow Chemical Co., Texas Oper. Polycarbonate Research Freeport, Texas Class 1000 Dow Chemical U.S.A. Research & Development of Freeport, Texas Polycarbonate Plastics Class 1000 DuPont de Mexico Packaging Sulfonyl Ureas Toluca, Mexico Class 10,000 DuPont Photomasks Photomask Lithography Danbury, Connecticut Class 1/10 E.I. du Pont de Nemours & Co., Inc. Agricultural Products Barranquilla, Columbia Environmental E.I. du Pont de Nemours & Co., Inc. Agricultural Products Cagua, Venezuela Environmental E-Systems, Inc. Military Electronics Assembly Garland, Texas Class 10,000 Eagle Picher Industries Lens Fabrication Miami, Oklahoma Environmental Eastman Kodak Digital Photographic Rochester, New York Class 10 Eastman Kodak Digital Photography Rochester, New York Class 100 Eaton Corporation Ion Beam Implantation Austin, Texas Class 100/1000 Eaton Corporation Semiconductor Equipment Manuf. Austin, Texas Class 100/1000 Eaton Semiconductor Lighting Systems Rockville, Maryland Class 10/100/1000 Environmental Protection Agency Pollution Research Chapel Hill, North Carolina Environmental Epitaxx-Division of JDS Uniphase Electronics Ewing, New Jersey Class 10,000/100,000 Eternal Technologies, Inc. Manufacturing Colonial Heights, Virginia Class 100/1000/10,000 Exxene Corporation Screen Printing Corpus Christi, Texas Class 100 Fanuc USA Corporation Silicon Wafer R & D Union City, California Class 10/100 FERF University Flat Panel Research Center Palm Bay, Florida Class 10/1000/10,000 Fisher Controls International Research & Development Austin, Texas Class 100 Flopure, Inc. Gas Panel Assembly San Antonio, Texas Class 10/100 Fusion Systems Etch Process Manufacturing Rockville, Maryland Class 10/100/1000 Gebex Corporation Photomask Lithography Irving, Texas Class 10/100/10,000 Gebex Corporation Photomask Lithography Irving, Texas Environmental Georgia Institute of Technology Research & Development Atlanta, Georgia Class 10/100 Georgia Institute of Technology Nanolithography Atlanta, Georgia Class 10
Gillette Manufacturing Boston, Massachusetts HVAC Re-Design Graham Magnetics High Density Tape Production Graham, Texas Class 10,000 Graham Magnetics, Carlisle High Density Tape Production N. Richard Hills, Texas Class 1000 Gray/Mitsubishi Developer Tube Coating Chesapeake, Virginia Class 10/100 Hercules Aerospace Paint Application McGregor, Texas Environmental Hitachi Semiconductor Integrated Circuit Assembly Irving, Texas Class 1000 Hitachi Semiconductor Integrated Circuit Assembly Irving, Texas Class 1000 HMT Technology Product Development Fremont, California Class 100,000 Honeywell/AlliedSignal Silicon Production Redmond, Washington Class 10/100 Honeywell Optoelectronics Gallium Arsenide Semiconductor Richardson, Texas Production Class 10 Honeywell Optoelectronics Fiber Optics Production Richardson, Texas Class 100/10,000 Honeywell Optoelectronics Military Electronics Production Richardson, Texas Class 100/10,000 Hughes Offshore Close Tolerance Hydraulic Houston, Texas Components Production Class 10,000 Hughes Tools Close Tolerance Hydraulic Houston, Texas Components Production Class 100,000 IBM Product Development Guadalajara, Mexico Class 100 IBM (B-650) Product Development Hopewell Jct., New York Class 1000/10,000 IBM Fishkill 330-D Sub Measurement Laboratory Hopewell Jct., New York Class 10 IBM-Data Systems Division Metal Artwork Poughkeepsie, New York Class 100/10,000 IBM-Data Systems Division Wet Lab Poughkeepsie, New York Class 10,000 In-Focus Systems N/A Tualatin, OR Class 100/1,000/10,000 Input/Output, Inc. Seismic Tool Manufacturing Stafford, Texas Class 100 thru Class 100,000 Integrated Gas Systems High Purity Piping Houston, Texas Class 100 Integrated Gas Systems High Purity Piping Houston, Texas Environmental Integrated Pharmaceutical Systems Pharmaceuticals King of Prussia, Pennsylvania Class 10,000/100,000 Intel Corporation Semiconductor Fabrication Rio Rancho, New Mexico Class 100/1000 IntelliEPI N/A Richardson, Texas Class 1000 Intermedics, Inc. Medical Implants Freeport, Texas Class 10,000 International Resistive Corp. Resistor Fabrication Corpus Christi, Texas Class 100 Iowa State University Research & Development Ames, Iowa Class 100 JDS Uniphase – Epitaxx Division Optical Switch Ewing, New Jersey Class 1,000/10,000 Kachina/DPR Wafer Refabrication Austin, Texas Class 1000 Kajima/Hitachi Product Development Norman, Oklahoma Class 1000 KAO Infosystems 3.5" Disk Manufacturing Plymouth, Massachusetts Class 10,000 KAO Infosystems Magnetic Media Coating Plymouth, Massachusetts Class 100/1000 KAO Infosystems High Density Diskette Mfg. Plymouth, Massachusetts Class 10,000 Kemet Electronics Microelectronics Manufacturing Mexico Class 1000 Kent State University Liquid Crystal Institute Kent, Ohio Class 100/1000/10,000 Koch Specialty Chemical Company Chemical Manufacturing Houston, Texas Class 10/100 Lawrence Livermore Natl. Labs Research & Development Livermore, California Class 10,000 Lawrence Livermore Natl. Labs Wafer Research Livermore, California Environmental Lawrence Livermore Natl. Labs Research Livermore, California Environmental Lawrence Livermore Natl. Labs Metrology Livermore, California Class 1000/10,000 Libbey-Owens-Ford (L-O-F) Plastic/Glass Lamination Collingwood, Ontario Class 100/1000 Libbey-Owens-Ford (L-O-F) Plastic/Glass Lamination Sherman, Texas Class 100 Libbey-Owens-Ford (L-O-F) Plastic/Glass Lamination Lindsay, Ontario Class 100 Libbey-Owens-Ford (L-O-F) Plastic/Glass Lamination Toledo, Ohio Class 100 Libbey-Owens-Ford (L-O-F) Plastic/Glass Lamination Mexicali, Mexico Environmental Litton Resource Systems Thick Film Circuit Production Houston, Texas Class 100 Lockheed Martin (formerly LTV) AeroSpace Electronics Grand Prairie, Texas Class 10 Loral Vought Systems Aerospace Electronics Grand Prairie, Texas Class 1000 Los Alamos Laboratories Electronic & Laser Research Los Alamos, New Mexico Class 100 LRS-Western Atlas Internat’l Fiber Optical Cable Bonding Alvin, Texas Class 100,000 LTV Missiles & Electronics Research & Development Grand Prairie, Texas Class 1,000 LTV Missiles & Electronics Aerospace Electronics Garland, Texas Class 1000/10,000 Lucent Technology Chemical Machine Polishing Orlando, Florida Class 1/10 Lucent Technologies/Cirent CMP Area Orlando, Florida Class 10 MacMillan, Inc. Defense Rockville, Maryland Class 100,000 Marcus Thomas & Company Semiconductor Research Houston, Texas Environmental Martin Marietta Laser/Optics Warner Robins, Georgia Class 10,000 Matsui America, Inc. Process Support Piping Elk Grove Village, Illinois N/A MCC Research & Development Austin, Texas Class 100/10,000 MCC Research & Development Austin, Texas Class 10,000 McGhan Medical Medical Device San Jose, Costa Rica Class 10,000 Mead Office Systems Ink Jet Printing Plano, Texas Environmental Medrad Medical Devices Indianola, Pennsylvania Class 10,000/100,000 Medrad Medical Devices Expansion Indianola, Pennsylvania Class 10,000 MEMC Microelectronics Pasadena, Texas Class 1000/10,000 Merck Sharp & Dohme Pharmaceuticals Elkton, Virginia Environmental Merck & Company Pharmaceuticals Elkton, Virginia Class 100/1,000 MicroDisplay Corporation Flat Panel Display R & D Richmond, California Class 100 MicroDisplay Corporation Miniature Information Displays (MIDs) San Pablo, California Class 10/100/1,000 Millipore Microelectronics Facility Plano, Texas Class 10/100/1000 Mobay Chemical Corporation Polycarbonate Manufacture Baytown, Texas Class 1000 Mobay Chemical Corporation Polycarbonate Manufacture Baytown, Texas Class 100,000 Mobay Chemical Corporation Polycarbonates Baytown, Texas Class 10,000 Monolithic Memories Integrated Circuit Santa Clara, California Class 10,000 Morgan Semiconductor Gallium Arsenide Wafer Fab. Garland, Texas Class 1000 Motif, Inc. LCD Manufacture Wilsonville, Oregon Class 100/10,000 Motorola, Inc. Packaging Lab Arlington Heights, Illinois Class 100/1000 Motorola, Inc. Electronic Research Schaumburg, Illinois Class 100,000 Motorola, Inc. Electronic Assembly Schaumburg, Illinois Class 100/1000 Motorola, Inc. Electronic Component Manufacturing Chung-Li, Taiwan Class 100/500/1000 Multiplex Optoelectronics South Plainfield, New Jersey Class 1000/10,000 NanoOpto Optoelectronics Somerset, New Jersey Class 10/100/1000 NASA - Johnson Space Center Instrument Cleaning Houston, Texas & Calibration Class 100/1000/10,000 NASA - Johnson Space Center Development of Close Tolerance Houston, Texas Hydraulic Components Class 100 NASA/Johnson Engineering Product Preparation Zone Houston, Texas Softwall Environment National Research Council-Canada Metallurgy Ottawa, Ontario, Canada Class 100 National Semiconductor Corp. Semiconductor Fabrication Santa Clara, California Class 1/100 National Semiconductor Corp. Mask Making Annapolis Jct., Maryland Class 1 Naval Research Lab Shuttle Payload Washington, D.C. Class 1000 nCHIP Superconductor Research Fayetteville, Arkansas Class 100/1000 Northern Telecom Product Development Saskatoon, Saskatchewan N/A Canada Northern Telecom Product Development Saskatoon, Saskatchewan, Canada Class 10,000 Northrop Grumman Electronic Assembly Pittsburgh, Pennsylvania Class 100 Northrop Grumman Electronic Assembly Pittsburgh, Pennsylvania Class 1,000/10,000 Nysco Laboratories Pharma Production Hsin Chuang, Taiwan (ROC) Class 100,000 Ohio State University Research & Development Columbus, Ohio Class 100/1,000 Oklahoma State University Research & Development Stillwater, Oklahoma Class 1000 OMJ Pharmaceuticals Pharmaceuticals San German, Puerto Rico Class 100/1000 OnTrak Systems Equipment Manufacturing Milpitas, California Class 10/100 OnTrak Systems Semiconductor R & D Milpitas, California Class 10/100 Optical Coating Labs, Inc. Optical Coating Santa Rosa, California Class 100,000 Optical Coating Labs, Inc. Plastic Products Santa Rosa, California Class 100 Optical Imaging Systems Flat Panel Display Manufacture Northville, Michigan Class 10/100/1000/10,000 Optical Switch Corporation Semiconductor Bedford, Massachusetts Class 1,000/10,000 OpticNet, Inc. MEMS Facility Hayward, California Class 10/1000 Orbital Scientific Research Dulles, Virginia Class 10,000/100,000 Orbitek Engineering Semiconductor Support Manuf. Area Austin, Texas Class 100 Parker Hannifin Ultra High Purity Valve Manufacturing Huntsville, Alabama Class 100 Pennsylvania State University Submicron Processing Facility University Park, Pennsylvania Class 10 to Class 100,000 Photronics, Inc. Photolithography Brookfield Center, Connecticut Class 1 Photronics, Inc. Photomask Lithography Milpitas, California Class 10/100/10,000 Photronics, Inc. Photomask Lithography Milpitas, California Class 10/100 Photronics, Inc. Photolithography Milpitas, California Class 10/100 Photronics, Inc. Photolithography Brookfield Center, Connecticut Class 10/1000 Photronics, Inc. Photolithography Dallas, Texas Class 1 thru Class 100 Photronics, Inc. Photomask Back-End Colorado Springs, Colorado Class 10,000 Photronics, Inc. Pellicle/Manufacturing Allen, Texas Class 1/10 Photronics, Inc. E-Beam Room Colorado Springs, Colorado Class 10 Photronics, Inc. Photolithography Austin, Texas Class 1/100 Photronics, Inc. Photolithography Facility Maintenance Austin, Texas Class 1/100 Planar Systems Flat Panel Displays Beaverton, Oregon Class 10 Planar Systems Flat Panel Displays Beaverton, Oregon Class 100/10,000 Polytronics Electronic Assembly Richardson, Texas N/A Praxair Gas Cabinet Manufacturing San Antonio, Texas Class 100 Precision Robots, Inc. Semiconductor Mini-Environments Billerica, Massachusetts Fab Tool Class 1 Precision Robots, Inc. Semiconductor Billerica, Massachusetts Class 10,000 Princeton University (Turner Construction) E-Quad Princeton, New Jersey Class 100/1,000 Red River Army Depot Defense Texarkana, Texas Class 100,000 Rexham, Inc. Product Development Mathews, North Carolina Class 100/10,000 Richardson Vicks Cooling Tunnel Mexico City, Mexico Class 10,000 Rocap Pharmaceuticals Orlando, Florida Class 100/10,000 Rollins Environmental Services Computer Room Deer Park, Texas Class 10,000 sVision, Inc. Flat Panel Display Twinsburg, Ohio Class 100/1000 Sage Technology Horizontal Cleanrooms Smyrna, Georgia Class 10 Sawtek, Inc. Radio Frequency Drive San Jose, Costa Rica Class 1000 Sawtek, Inc. M/I Assembly Apopka, Florida Class 100 Sawtek, Inc. Assembly Apopka, Florida Class 10 Schering Plough Pharmaceuticals Mexico City, Mexico Class 100/1000 Servitex Laundry Facility Atlanta, Georgia Class 1/10/100 Sierracin Plastic/Glass Lamination Sylmar, California Environmental Sierracin Aircraft Canopy Lamination Sylmar, California Class 1000 Silicon Material Services Silicon Wafer Fabrication Garland, Texas Class 10 Silicon Material Services Silicon Wafer Fabrication Garland, Texas Class 100 Silicon Video Flat Panel Displays Cupertino, California Facility Selection Survey Silicon Video Flat Panel Displays South San Jose, California Scale-Up / Certification Sony AMD Wafer Manufacturing Austin, Texas Class 10 SubMicron Systems Microelectronic Equipment Mfg. Allentown, Pennsylvania Class 1/10/100 Sumitomo Electric Optical Cable Res. Tr. Park, North Carolina Class 1000 Sundstrand Data Controls Government Testing Redmond, Washington Class 10,000 Temp Glass Southern Plastic/Glass Lamination Arlington, Texas Environmental Texas A & M University Biological Research College Station, Texas Class 100 Texas A & M University Plant Tissue Culture Research College Station, Texas Class 100 Texas Air Quality Control Air Sample Lab Austin, Texas Class 1000 Texas Instr.-Dallas Chem. Ctr. Chemical Packaging Dallas, Texas Class 10/10,000 Texas Instruments Electronic Assembly Richardson, Texas Class 100 Texas Instruments Product Development Richardson, Texas Class 100,000 Texas Instruments Electronics Assembly Plano, Texas Environmental Texas Instruments Product Development Cypress, Texas Class 100 Texas Instruments Integrated Circuit Production Plano, Texas Environmental Texas Instruments Integrated Circuit Production Lubbock, Texas Environmental Texas Instruments Chemical Products Richardson, Texas Class 10 Texas Instruments Etch Operations Attleboro, Massachusetts Class 100 Thomson Consumer Electronics TV Picture Tube R & D Lancaster, Pennsylvania Class 100 Triquint Semiconductor Radio Frequency Drive San Jose, Costa Rica Class 1000 Triquint Semiconductor M/I Assembly Apopka, Florida Class 100 Triquint Semiconductor$ Assembly Apopka, Florida Class 10 Ultratek Screen Printing Corpus Christi, Texas Class 1000 Unicor Corporation Humidity Sens. Adhesive Assembly Bastrop, Texas Environmental Union Carbide Polyolefins Packaging Seadrift, Texas Class 100,000 Union Carbide Polyolefins Packaging Seadrift, Texas Class 100,000 Union Carbide Tank Car Cleaning Facility Port Lavaca, Texas Ultra Clean Environment Unit Instruments Instrumentation Richmond, Virginia Class 100 University of Alabama Mineral Research Tuscaloosa, Alabama Class 100/1000 University of Arkansas Research & Development Fayetteville, Arkansas Class 100 University of California Photo/Thin Films Riverside, California Class 100/1,000 University of Central Florida Research & Development Orlando, Florida Class 1000 University of Colorado @ Boulder Astrophysics Boulder, Colorado Class 1000/10,000 University of Houston Wafer Research Houston, Texas Class 100 University of Houston Space Vacuum Epitaxy Cntr. Houston, Texas Class 10,000/100,000 University of Houston Low Humidity Furnace Room Houston, Texas Class 100 University of N. Carolina-Charlotte Research & Development Charlotte, North Carolina Class 1000 University of N. Carolina-Charlotte Metrology Charlotte, North Carolina Class 100,000 University of Tennessee Nanophase Material Sciences Oak Ridge, Tennessee Class 1,000 University of Texas - Arlington Ion Implantation Arlington, Texas Class 10/100 University of Texas – Arlington R & D – Student Research Arlington, Texas Class 100/1,000 University of Texas - El Paso Microelectronic Research El Paso, Texas Class 100 Valex Corporation Ultra High Purity Piping Ventura, California Class 100 Varian Semiconductor Fabrication Fremont, California Class 100 Varo Semiconductor, Inc. Semiconductor Development Garland, Texas Class 100 VDO Instruments Close Tol. Inst. Silk Screening Mississauga, Ontario, Canada Class 100,000 Virginia Commonwealth University Research and Development Richmond, Virginia Class 100;/1,000 Process Laboratories Visiting Nurse Association Pharmaceutical Packaging Houston, Texas Class 1000/10,000 William M. Rice University Geological Carbon Dating Houston, Texas Class 100,000 William M. Rice University Mass Spectroscopy Houston, Texas N/A William Marsh Rice University Hulet Cleanroom Lab Houston, Texas Class 100 William Marsh Rice University Abercrombie Cleanroom Houston, Texas Class 1000
Cleanroom Softwall Systems…
Cleanroom Softwall Systems…
Bill Johnson (Cleanroom Facilities) 2012-01-24 20:32:35
What’s Unique about Cleanroom Softwall Systems
There are many things that you may need inside of a cleanroom and cleanroom softwall systems are one of them. Whether you need it to divide patients or employees, they will provide you with a safe way to create temporary walls within the cleanroom. They will also ensure that the particulate ratio is not affected by bringing them into the room.
What Cleanroom Softwall Systems Are Cleanroom softwall systems
These work similar to standard cubicle walls except that they are designed using aluminum and often vinyl as a way of creating a cleanroom environment. They can be extremely sturdy and will come with glides so that they can easily move where they are needed.
The look of the cleanroom softwall systems can differ from company to company as well as through various features that you can include on them. Some of the walls are clear while others are white. You can choose how you want them to be aesthetically and choosing one way or another may help you to narrow down companies in which to get them from.
Why You Need Cleanroom Softwall Systems
There are many reasons that you would need cleanroom softwall systems. Whether you are a laboratory or an electronics assembly plant, you may not want everyone in a single area of the cleanroom. It’s hard to establish corners for the various departments and it may be easier to give some projects some privacy. This is where the softwall systems come in. You can pop them up wherever they are needed. Should an area need to grow, you can simply move the walls. If you need to expand even further, all you need is a few more walls.
You will need walls that maintain the particulate levels and so that means you can’t have just any ordinary modular wall. The wall which you do purchase needs to fit within the class of your ISO level. Some are designed to go up to a level 4 and others go all the way up to a 9, so it’s important to find the one that you need.
Features on Cleanroom Softwall Systems
There are many different features that can come with cleanroom softwall systems that make them more adaptable to a cleanroom. Often, companies will ship them with all of the added features already installed so that a cleanroom can simply unpack them, bring them into the room and begin using them immediately.
Such features include:
- Lighting systems
- Ceiling Systems
- Fire suppression systems
- Roller tracks
- Removable filters
- Anti-static vinyl curtains
- Heating and A/C
These features can help a cleanroom easily expand without worrying about creating another environment because these cleanroom softwall systems can be designed as a completely modular, portable cleanroom that can be moved anywhere that it is needed.
Cleanroom softwall systems
Digital Air Control is a design-builder of cleanroom facilities and can assist you in your cleanroom needs. Contact us today to see how we can assist you in your cleanroom needs.
Cleanroom Project Management…
Cleanroom Project Management…
Bill Johnson (Cleanroom Facilities) 2012-01-24 20:20:40
Cleanroom Project Management Ensures the Job Is Done Right
When you are having a cleanroom installed, the last thing you want to find out is that it wasn’t designed properly. Whether you are dealing with electronics or a medical profession, a cleanroom needs to be designed to the specifications of a certain ISO level. If the specifications are wrong in any matter of things, it could mean expensive fixes. The way to ensure that the project goes as planned is to hire a cleanroom project management firm.
What Cleanroom Project Management Covers Cleanroom project management
- The design of the cleanroom
- Process Equipment Matrices
- Decontamination processes
- Construction Protocols
- Training of personnel
- Cleanroom Protocols
- Process Equipment Infrastructure
- Process Equipment Fit-up
- Cleanroom Performance Testing
The design of the cleanroom is a very daunting task as there are so many pieces of the puzzle. There are mechanical systems, ceiling systems, process systems, lighting systems and many other systems to take into consideration. Then there is the general layout of the facility so that it has a good product flow from workspace to workspace. There is also everything that goes into the facility including furniture and equipment. To cover all bases, cleanroom project management firms are hired.
Decontamination processes are another important part of a cleanroom and therefore covered by cleanroom project management. They will help to establish what kinds of protection needs to be worn by the personnel, how they will get dressed and what kind of decontamination air showers and such they will need to go through before entering the cleanroom.
Finally, there is the training of personnel. This will include what they can and cannot bring in with them. On higher ISO level cleanrooms, a simple pencil can be enough to create too many particulates into the atmosphere so training is very important. The training by the cleanroom project management team will also encompass how to monitor the systems in place. This way, if sirens or alarms go off, they know proper procedure for handling everything.
Where to Get Cleanroom Project Management
There are many cleanroom project management firms available throughout the globe. Many of them have years of experience dealing with laboratory environments and controlled atmospheres. It’s best to try and find one that has experience with the same kind of cleanroom as you are building. This way, there aren’t medical professionals offering advice on technical optics and vice versa. Get references from anyone claiming cleanroom experience and check the references. In checking the references, you can also discuss find friends in the industry to check in with and learn their lessons learned.
How Much Cleanroom Project Management Costs Cleanroom project management
Digital Air Control is a design builder of cleanroom facilities and can assist you with cleanroom project management. Our staff have been in cleanrooms since the 1980’s and our experience can be beneficial to your cleanroom project.
Cleanroom Planning Guide…
Cleanroom Planning Guide…
Bill Johnson (Cleanroom Facilities) 2012-01-24 20:09:47
Making a Cleanroom Planning Guide
There are a lot of aspects to a cleanroom, so a cleanroom planning guide will help to make sure you’ve covered all of them. You can create your own or go with a planner. Either way you choose, you will want to plan all of the details of what will go into your cleanroom so that it is extremely efficient and fits within the rated class that your room needs to be designated as.
What a Cleanroom Planning Guide Consists of
Having a cleanroom planning guide will help you to plan every single part of the cleanroom. You will need to consider everything from:
- Process Equipment Matrix
- Process Utilities
- Gowning Room Requirements
- Temperature & Humidity Requirements
- Electrical Requirements
- Airflow Requirements
- HVAC Requirements
- Process Gases
- Bio Burden
- Cleanliness Requirements
- Systems & monitors
This is a very basic list as each category above has many, many subcategories.
The gowning room will be the room right before the cleanroom that employees use to get into their gowns, booties, and any other requirements for entering the cleanroom. The furniture within this room needs to be cleanroom approved otherwise additional particles will enter the cleanroom. A cleanroom planning guide will also include whether it is necessary to have an air shower and what kind of gowns will be needed as you design your gowning room.
Next is the HVAC system. You will need a system to not only filter the air but to remove a specific number of particles from the air. There are instruments that can be used to test the air quality on a regular basis but will only be necessary if the Filtration Systems are doing its job. The kind you will need will depend upon the ISO class of the cleanroom.
The equipment and furniture inside of the cleanroom will be part of the cleanroom planning guide. You will need to look at equipment, desks, chairs, keyboards and various other kinds of equipment. Nothing can be of a fibrous material so wood and cloth items are immediately out. Anything else that you need should be listed so that you can find safe cleanroom alternatives for them.
Systems and monitors will be the most comprehensive part of the cleanroom planning guide. You will need humidification systems, vacuums, pressure monitors, and many other bells and whistles. This is so that the particulate percentage is maintained at all times. Extra moisture into the air or a sudden pressure change could be detrimental to the work inside the cleanroom and therefore must be monitored.
Where to get a Cleanroom Planning Guide
If you have gone through a cleanroom planning guide at another plant and are planning on duplicating it in a new location, the same guide will typically apply. There are also cleanroom construction companies inspectors that will provide you with a guide so that they can know that you’ve at least attempted to cover all bases before they come in and do an inspection. In addition to those methods, there are various cleanroom construction companies and project management firms that will have a comprehensive guide to go over with you once they have been hired on for the task.
Digital Air Control is a design builder of cleanroom facilities and can assist you in developing all the necessary information for a cleanroom planning guide. We can provide you with a planning guide and can assist you in completing the guide itself. We can use the planning guide to develop a scope of work and can provide firm fixed pricing for the cleanroom construction costs. Contact us today for your cleanroom needs.
Cleanroom Gowning Furniture…
Cleanroom Gowning Furniture…
Bill Johnson (Cleanroom Facilities) 2012-01-24 19:47:38
Cleanroom Gowning Furniture Is a Requirement Cleanroom gowning furniture Why Cleanroom Gowning Furniture is Necessary
When you have employees that are putting on gowns, you need to give them a place to sit and a place to properly discard things. If the furniture you have placed in the gowning room is inappropriate for a cleanroom, however, then the gowns are completely useless.
Fibrous material can easily cling to a gown. When the gown then enters the cleanroom, these particles fall into the air and can lead to problems within the cleanroom. Filters are designed to remove particles from the air, however if too many enter at once, the items that are in the clean environment will be jeopardized. Cleanroom gowning furniture is therefore necessary.
Kind of Cleanroom Gowning Furniture
The best way to decide what kind of cleanroom gowning furniture is needed is to go into a room with the kinds of gowns that are needed to be worn and decide what you need. Will you need a bench? A waste basket? A supply dispenser? You want to make the gowning room as comfortable as possible so it’s important to consider what furniture you will place.
The other thing to consider is the effectiveness of the room. If you have twenty employees that show up to work at the same time, one bench will not be sufficient. You want to plan the room so that it is time-productive. If that means multiple benches or something that bends around the shape of the room to offer multiple places to sit, then this should be considered.
Where to Buy Cleanroom Gowning Furniture Cleanroom gowning furniture
There are various places where you can buy cleanroom gowning furniture, but make sure you purchase from companies that are familiar with cleanroom gowning protocols. If you cannot find a local location you can easily have something shipped to your cleanroom. This will help you to offer an area for employees to don their appropriate apparel without disrupting the integrity of the cleanroom in the process.
Cleanroom gowning furniture
Digital Air Control is a design builder of cleanroom facilities and our staff have developed cleanroom protocols for many facilities around the world. Contact us today to see how we can assist you in your cleanroom facilities.
Cleanroom Design Build…
Cleanroom Design Build…
Bill Johnson (Cleanroom Facilities) 2012-01-24 19:34:43
Cleanroom Design Build Assistance
There are professionals in the cleanroom industry that will provide cleanroom design build assistance to companies to ensure that a cleanroom is properly constructed. Depending upon the purpose of the cleanroom, you need to make sure that the correct amounts of particulates are being filtered through the air otherwise you could be compromising your work. A cleanroom design build can be very complex so hiring a company that specializes in it can be a significant help.
What a Cleanroom Design Build Encompasses
Whether you’ve worked in cleanrooms before or not, there is a lot that goes into them. The floor, the ceiling, the lights, and everything in between needs to be specifically designed for a cleanroom, otherwise performance can be compromised. After all, a cleanroom is supposed to be clean – clean of particulates, dust and anything else that could damage equipment or lab results. A cleanroom design builder can ensure that you cover all of your bases without forgetting anything.
The first thing that is necessary with a cleanroom design build project is to establish what level of a cleanroom you are operating in. There are many different levels. For ISO Classification the lower the level, the lower number of particulates per cubic foot/meter that should exist in the air. Under the Federal Standard 209E, the number actually tells you how many particles are allowed per cubic foot of air. For example, a Class 100 area is allowed a maximum 100 each 0.5 micron sized particles and larger. From there, you can begin determining everything else you need in place including:
- HVAC systems
- Pressure sensors
- Humidification systems
- Ceiling systems
- Flooring Systems
- Process Systems
- Control Systems
Every cleanroom constructed is to support the process being performed inside the clean space. Microelectronic cleanrooms are totally different from pharmaceutical cleanrooms. The approach, the design, the documentation are all done differently. A validated cleanroom is even more intensive on the paperwork and approvals.
Everything that goes inside of a cleanroom needs to be considered. A cleanroom design build contractor can take you through every step of the way so that you are even going into the types of furniture on the inside as well as air showers to decontaminate employees going into the room.
The internet has many companies claim to be cleanroom design build experience, so make sure you understand their team members to see what facilities they have constructed cleanrooms facilities for. You will want to find a reputable company that has experience behind them. The best way to do this is to ask for references and call the other cleanrooms to see how satisfied they are with the company in question. This will ensure that you are getting quality for the money that you are spending.
Many building companies will offer cleanroom design build approaches. If they don’t they will usually be able to point you to a firm that does. When you get recommendations from reputable building companies, it often helps take the guesswork of quality out of the equation. Once you find a few companies, you can start getting estimates. It’s important that you get at least two estimates on building your cleanroom so that you know if you are getting a good deal or not.
Whether you want a cleanroom designed with an ISO Class 1 or an ISO class 9, you should be able to get the design and build that you want so that you can trust the conditions and pass inspections upon having it built. Knowing exactly what you want inside will help the company to build and advise giving you what you imagined. It’s always important to have it done right the first time, even if it means going to a higher level to allow for growth.
Digital Air Control has a staff that has been constructing cleanroom facilities since the late 1980’s. Our team members were taught by innovators that constructed cleanroom areas back in the late 1960’s. Contact us today about your cleanroom facility needs.
Pharmaceutical Clean Room Facilities…
Pharmaceutical Clean Room Facilities…
Bill Johnson (Cleanroom Facilities) 2012-01-12 00:41:24
Pharmaceutical Clean Room Facilities
Clean rooms are designed to provide the most controlled and contaminant free environment for a variety of manufacturing, research, and pharmaceutical processes. In an effort to maintain the sanctity of the clean rooms, HEPA filters are used to aid in the circulation of the least contaminated air, the wearing of specific clean room garments and strict protocol. A pharmaceutical clean room requires special attention to prevent the admittance of outside contaminants into these rooms.
Importance of Pharmaceutical Clean Rooms
Clean rooms are an invaluable investment for all industries that construct them in an effort to have the most contaminant free environment to fit their needs. In the case of a pharmaceutical clean room the integrity of their construction is of the utmost importance as the research and processes being dealt with inside these clean rooms involve medical research and applications. The integrity of these processes cannot be compromised by the faulty or improper construction of the clean rooms in which they are being dealt with.
Pharmaceutical
In order for the multiple medical processes and research applications that take place in a pharmaceutical clean room to be of the highest integrity it is vital that the construction of these rooms, as well as their maintenance is not compromised. Prior to the construction of a pharmaceutical clean room it is important that all processes that will be taking place in the clean room be taken into consideration for proper layout of these rooms. With an improper layout, depending on the type of processes being done, there is the potential risk of cross-contamination with could result it invalid research as well as products that must be remade. Without the proper foresight when planning the layout for these clean rooms the negative financial impact could be felt at a later date.
Clean Room Maintenance
The proper pharmaceutical clean room has been designed and constructed. The surfaces are smooth and all edges are virtually seamless. The proper use of air heating, cooling, and circulation is installed and in use. With the use of walls created with such materials as stainless steel the ability to properly maintain the cleanliness and sanctity of these clean rooms will be easier to obtain. The regular cleaning and maintaining of all floors, walls, and surfaces of the clean room are not the only requirements for observing the strict requirements a clean room possesses. It is also vital to the integrity of the clean room that all individuals that enter a pharmaceutical clean room be dressed in the proper clean room attire.
Pharmaceutical Clean Rooms
Clean rooms that are constructed for any industry have strict regulations for their design, maintenance, as well as the strict guidelines that all that enter the clean rooms must follow. In the case of a pharmaceutical clean room these rules are even more important do to the fact that the research and processes that are being handling insides these clean rooms revolve around a variety of medical topics. Proper layout, maintenance, and the wearing of proper clean room garments all help to insure the stringent regulations that apply to the controlled environment of a pharmaceutical clean room.
Digital Air Control
Clean Room Solutions…
Clean Room Solutions…
Bill Johnson (Cleanroom Facilities) 2012-01-04 23:32:03
Clean Room Solutions Are Key To Keeping Your Clean Room Efficient And Contaminant Free
Maintaining a clean room is imperative for any operation that involves compounding materials or where the products that are being worked with, or produced, must be controlled for contamination. A clean room is one where the contamination of materials is controlled for. Environments such as laboratories, hospital or surgical rooms, must control for pathogens, chemical or biological agents and other infection control. Therefore, making a contaminant free environment becomes crucial not only for the products produced, but so too for the workers contained and working within the space. Several clean room solutions are available and continue to be improved upon to make your clean room run efficiently over time, and safely, for all of its inhabitants.
Having an efficiently operating clean room means that there are perpetual contamination controls in place for continuous monitoring that certifies the environment of any clean room environment. Making sure that the air flow and overall air quality is safe and contaminant free is not a onetime procedure. Having an instrument that continually checks for, and monitors the air in the environment, is imperative to control for any leaks in the system or contamination that may occur. Having the proper monitoring and regulatory systems in place is the only way to not only construct, but to maintain a fully functional, safe and quality, clean room. Making sure to utilize only the best in clean room solutions, is the best way to ensure one.
Whether you determine that a portable, modular clean room, or a permanent stationary clean room is the best for your operation, it is imperative that you design, construct and maintain the best clean room solutions within the environment. Determining the materials and particles that your clean room will be specifically targeting will give you a better understanding of what clean room solution is best for your space. Different contaminants need to be controlled for through different standards and means so knowing what you are trying to control for will give you a better overall design and lead to better monitoring of the environment once it is designed and constructed.
There are some overall key features that are included in clean room solutions. The target of any clean room is to run an energy efficient design that allows for single pass or recirculating airflow design. Prepackaged HVAC systems are a good way to ensure that you have a fully functional and appropriate air flow system to your clean room that will account for contamination. Having a prepackaged HVAC system means that you can control for a cleanliness range ISO class 5 to class 8 guaranteed. Pre-packaged systems are not always the end all be all. Most cleanroom facilities are specifically constructed based on the product's and production equipments needs inside the cleanroom envelope, therefore most cleanroom systems have to be designed and constructed to an exacting scale.
Once the clean room is operational, ongoing monitoring is as crucial as the design and construction. Monitoring the safety and efficiency of the room itself, must be done on a continual basis. No matter how efficient your clean room solutions are, there is always the risk of contamination. Knowing and controlling for any incident is the only way to control for it.
Digital Air Control is a design builder of cleanroom facilities. Our staff have constructed cleanroom facilities around the world. Cleanroom construction requires critical construction protocols to insure the end results. We can help your staff develop the requirements of your cleanroom facility based on your industry. Contact us today to see how we can assist your cleanroom construction.
Cleanroom Upgrades…
Cleanroom Upgrades…
Bill Johnson (Cleanroom Facilities) 2011-12-20 01:23:57
What Makes a Cleanroom a Cleanroom
A cleanroom is often defined as the room that prevents any type of dirt and other contaminants from entering. Rather, for a better definition, it is a room that has a controlled number of contaminants. Remember, contaminants exist everywhere and anywhere all over the world and not a single or complex series of machinery. It is safe to say that no matter how many cleanroom upgrades there are, there still will be contaminants. However, that does not mean to say that cleanroom upgrades will help in keeping the number of contaminants at a minimum.
Though, discussing the many types of cleanrooms would definitely take some time, especially if it’s in-depth, it’s not what this article was made for. It is and was made for the reading pleasure of those who would like to know what goes on inside cleanrooms and what makes up a cleanroom. After all, it may have gone through many cleanroom upgrades with many people still wondering what makes a cleanroom a cleanroom.
Basically, there are three keys that make a cleanroom, a cleanroom. First, the filtration system filters all of the incoming particles. Filtration systems vary from cleanroom to cleanroom and from place to place, depending upon its uses and requirements. The filtration system includes the altercation of the airflow and the air pressure of the area. The latter, being controlled and raised on a slightly higher level in order to ensure that particles are not sucked into the room and the former, making sure that if any harmful particles may have passed through the filtration system, it does not become airborne and therefore cause any trouble. The air pressure is controlled by using seals, strategically placed outside the room, while the air flow is controlled by preventing any sudden movements while inside the room. This includes walking fast, running, horse play and even moving the hands or any other part swiftly.
The use of the cleanroom is also important, as there are also cleanrooms available out there that are portable and can be moved from one place to another, and there are those that are built into a building and are used for more extensive purposes. A cleanroom designed for the manufacture of a certain product will not be applicable for another, and vice versa. Lastly, the entry room is just as vital as any part of the cleanroom itself. For, it is where the workers, people and products that are to go inside the cleanroom are rid of any harmful particles and contaminants. Without the entry room, the filtration system would simply just fail as it will have a hard time removing contaminants that are already inside the room itself, especially if it is in large amounts or concentrations.
Now that you know what cleanrooms are, you may now think that no matter how many cleanroom upgrades they may go through, cleanrooms will not be able to perfectly rid themselves of any bacteria, dirt, dust and other contaminants. There may be cleanroom upgrades to the filtration system, or to the entry room, or for its purposes. But still, it will all remain the same.
Digital Air Control is a builder of cleanroom facilities. Our staff has been building cleanroom facilities for over 20 years and have been involved in cleanroom installations around the world. Digital Air Control is your go to team for your cleanroom facility. Give us a call to discuss your cleanroom requirements and how we can help.
Cleanroom Construction Materials…
Cleanroom Construction Materials…
Bill Johnson (Cleanroom Facilities) 2011-12-20 01:19:28
Using the Proper Cleanroom Construction Materials
Any time that you need to design and build a cleanroom, it is very important that you choose the correct cleanroom construction materials to ensure that your room is as free of contaminants as possible. This includes all of the material used in building your cleanroom such as surface finishes, tables, walls, and floors themselves and any and all other surfaces. The materials chosen should be such that they will not be damaged by things set on them, or otherwise easily release particles into the air that could contaminate the air.
The goal of a cleanroom is not necessarily sterility, but air quality. In a cleanroom, the air is filtered to ensure that the level on particles of a certain size does not exceed a certain limit. These rooms are used in many scientific and manufacturing industries, especially in the manufacture of sensitive electronics and life sciences. In many of these areas, particles in the area can contaminate or damage sensitive electronic parts or specimens, so it’s important that they are protected. In order to do this, specific practices and cleanroom construction materials are used to avoid any contamination of sensitive equipment, parts, specimens, etc.
Cleanroom construction materials,
All of the cleanroom construction materials used, especially those on floors, must be resistant to liquids that may be spilled on them. In many of these rooms, there is the potential that acids and strong corrosives and solvents will be used. The floor must be able to stand up to potential spills to avoid the release of contaminants into the air, as well as to avoid the creation of a potential safety issue.
There will also be a need to filter the air. Any air coming into the room, or leaving and being re-circulated into the room, must be filtered. In this case, there are special air conditioning units and filters which are used in the construction of cleanrooms. These units and filters are designed to filter out the smallest particles in order to make certain the air in the cleanroom is as clean as possible. It’s also important that you make sure that your cleanroom is properly sealed, and that the air pressure in the room is positive. If you’ve chosen the proper cleanroom construction materials and built the room or building correctly, sealing up the joints and seems should be fairly easy, but it is extremely important. Should a leak develop, the positive air pressure will force air out, instead of allowing the contaminated outside air into the room.
Digital Air Control is a builder of cleanroom facilities. Our staff has been building cleanroom facilities for over 20 years and have been involved in cleanroom installations around the world. Digital Air Control is your go to team for your cleanroom facility. Give us a call to discuss your cleanroom requirements and how we can help.
Cleanroom Controls and Design Specifications…
Cleanroom Controls and Design Specifications…
Bill Johnson (Cleanroom Facilities) 2011-12-20 01:14:22
Understanding Cleanroom Controls and Design Specifications
Cleanrooms are constructed mainly for the purpose of scientific studies and related applications. They are used by most manufacturing industries involved in semiconductor, nanotechnology, displays, bio tech, pharmaceutical or wafer fabrication. They are made to ensure that the area on which scientific work is done is under controlled environmental aspects. This is extremely important to guarantee that scientific evaluation will yield valid results. That is why cleanroom controls have to be closely looked into in the planning and design of a cleanroom. There are at least three basic environmental aspects that have to be covered when defining the controls set for a cleanroom and these are air, temperature, and humidity.
Air filtration is one cleanroom control that has to be carefully considered. The cleanliness of the room is defined by the amount of clean air that is mixed with contaminated or return air. Air in a cleanroom is filtered by means of High Efficiency Particulate or HEPA filter. Another alternative for the HEPA filter would be the Ultra Low Particulate or ULPA filter. These filters are usually rated in the range of 99.99% efficiency for particles of size 0.3 microns and above. The level of cleanliness the rooms gets is directly proportional to the desire results inside the cleanroom envelope. Another advantageous feature that air filtration brings is the pleating effect. Pleating effect is when the filtered air is blown in a jet stream manner. The result of which causes multiple air streams to uniformly moves away from the filter face.
Temperature is also another cleanroom control that most cleanrooms need to have. Often there is an allowable temperature range that has to be maintained inside the cleanroom. This is for the reason that most scientific concepts are directly affected by temperature. This is especially for the microelectronics industry. Pharmaceutical facilities also have to keep the temperature within a certain range in order to ensure the life and quality of chemicals they are using. If there are no specific requirements or preferences that the owner wants to implement, temperature ranges are then set according to human factors. They set them to a level that the people working on the cleanroom would be comfortable at.
Lastly, humidity control also plays an important role in keeping the cleanroom functional and efficient. Humidity is usually defined as the wetness or dryness of the air. The mixture of water vapor and air particles make up the composition of humidity. This cleanroom control is dependent in to which the cleanroom is intended for or the processes that will be done inside the room. This is usually in the range of forty to sixty percent with plus or minus five percent variation. Like temperature control, this is extremely important because it also affects a great deal of scientific concepts and failure to maintain this in allowable level may give you unreliable scientific results.
In general, these cleanroom controls are a form of restrictions that are very vital in keeping a cleanroom operational and to guarantee the quality of output that the owner wishes to achieve in building the cleanroom.
Digital Air Control is a builder of cleanroom facilities. Our staff has been building cleanroom facilities for over 20 years and have been involved in cleanroom installations around the world. Digital Air Control is your go to team for your cleanroom facility. Give us a call to discuss your cleanroom requirements and how we can help.
Filtration Systems of Cleanrooms…
Filtration Systems of Cleanrooms…
Bill Johnson (Cleanroom Facilities) 2011-12-20 01:08:50
Filtration Systems of Cleanrooms
Cleanrooms exist for the sole purpose of manufacturing products that cannot be manufactured and assembled anywhere else. These products, such as computer hardware, from the hard-disks, to the memory chips and basically, every part that comprises the CPU would malfunction and would not be able to exist if not for these cleanrooms. They are assembled and tested for any malfunction in such rooms, and as such, cleanrooms are required to be as clean as they can be. This, though, can only be accomplished if the cleanroom filtration system functions as well as it should. A cleanroom isn’t a cleanroom without its filtration system. The cleanroom filtration system ensures that the cleanroom fulfills its original purpose, and that is, to be a safe, hazard-free, and dust-free environment fit for the manufacture of pharmaceutical and chemical products, as well as those that were mentioned above. If not for the cleanroom filtration system, the cleanroom would simply just be filled with dust and other particles and it would not be able to fulfill its purpose. It is what makes the cleanroom a cleanroom. Though, the cleanroom filtration system isn’t just a single pipe or a single machine that weeds out all the harmful particles out of the room. Rather, it is the intricate combination of air pressure, air flow, filtration of particles and specially designed clothes for the workers inside that ensure minimal dust and particle formulation. In most cleanrooms, the filtration system starts with the air pressure. Because of its nature, most cleanrooms have slightly higher air pressure compared to other levels in the surrounding area or building. The pressure is kept high to make sure that dust and other particles do not enter the room. It is accomplished through a series of seals placed outside of the room, ensuring the contaminants are not sucked into the room itself. Also, the air flow is controlled specifically to make sure that contaminants themselves do not become airborne and therefore, prevent them from disturbing the workers and the products inside the cleanroom. Of course, not to be forgotten on the discussion surrounding cleanroom filtration would be the filters themselves. This is the heart and soul of the cleanroom filtration system, which is the main reason why cleanrooms even exist. They work much like other filters out there, only better, being able to filter out 99.97% of airborne particles larger than 0.3 micrometers in diameter, or that’s about smaller than dust particles. In other, more strict cleanrooms, they could even go as long as 0.2 micrometers in diameters and even lower, further preventing any dust and harmful contaminants from entering the room. Lastly, though, the workers are the last line of defense of the cleanroom filtration system. Workers are required to wear specifically designed clothing meant for use only in cleanrooms. This clothing is as clean as possible and does not contain any harmful particles. Also, the workers are disciplined to follow a cleanroom protocol and told never to do any sudden movements, run or even walk fast inside the cleanroom and are required to do only controlled and subtle motions. Digital Air Control is a builder of cleanroom facilities. Our staff has been building cleanroom facilities for over 20 years and have been involved in cleanroom installations around the world. Digital Air Control is your go to team for your cleanroom facility. Give us a call to discuss your cleanroom requirements and how we can help.
HVAC Control Expert…
HVAC Control Expert…
Bill Johnson (Cleanroom Facilities) 2011-12-12 01:08:05
When Constructing Your Cleanroom It Is Important To Hire A HVAC Control Expert
Cleanrooms are those rooms within some industries whereby all things must be held constant for the consistency of the product, or sometimes for the safety of the employees. Cleanrooms are production places where if one of the conditions within them is not held constant and controlled for, the entire production process at best will be halted, at worst, the results can be disastrous. If you are in need of a cleanroom for your operations, for whatever reason, knowing how to construct it perfectly is the first hurdle. Hiring an HVAC Control Expert may be the only way to ensure that the HVAC, an integral component is constructed properly.
A cleanroom is only as efficient as the construction of it. There are some industries that for which cleanrooms are imperative. Knowing what sorts of rules and regulations need to be in place prior to the planning and construction of your cleanroom will save you cost in the long room. Hiring an HVAC Control Expert who knows how to construct a cleanroom, and most importantly one that is specific to your industry is the best way to make sure that all standards are met.
There are a vast number of different options of HVAC systems for your cleanroom. Each concentrates on a different aspect of operations for a cleanroom, depending on what the needs for it are. Being that keeping your cleanroom contamination free both on the exterior and the interior of it, the proper HVAC unit is perhaps one of the most integral operational systems within your cleanroom. An HVAC Control Expert will know how to set up your system to meet the demands of the operations contained within.
Although hiring an HVAC Control Expert in this atmosphere may seem like a needless expense, if your HVAC is not controlling for contaminants or for hazards within and outside of your cleanroom, the potential for cost can be astronomical. Knowing what potential hazards you can encounter and how to combat them can potential save you costs not foreseen. Only an expert will know the exact industry standards and potential hazards that can be attached.
If you are constructing a cleanroom for your operations, having a cleanroom that works efficiently and effectively is the only way to safeguard not only your production, but your employees. Make sure to hire an HVAC Control Expert to foresee the potential contaminants and dangers of your cleanroom. The proper ventilation, heating and cooling of your cleanroom can potentially be the most integral part of the processes within it. In the end, it can determine the quality, or lack thereof, the your resulting products. Any time you hire a professional make sure to check out their previous endeavors as well as their references to make sure that they are qualified and knowledgeable. Planning ahead, will in the end save you time, cost and a huge headache.
Digital Air Control is a design builder of cleanroom facilities and can assist you with programming your cleanroom for optimal performance. We can also perform a review of your existing cleanroom facility to show you ways to optimize your cleanroom or production facility.
Cleanroom Market Segments…
Cleanroom Market Segments…
Bill Johnson (Cleanroom Facilities) 2011-12-10 20:59:02
Cleanroom Planning, Implementation, and Market Segments
In the industry, there are several cleanroom market segments: scientific research, nanotechnology, life sciences, biotechnology, microelectronics industries, dispensary facilities, university and government. Hospitals also must have cleanrooms free of contamination pollutants and represent a market segment as well. In these areas, the use of cleanrooms is necessary because the dust, bio burden and other particles may have a negative effect on product, environment, testing and evaluation.
A clean room is a sealed enclosure under positive pressure related to ambient. Cleanroom market segments have different designs depending on the products or services being produced in the environment. The materials contained in cleanrooms are typically sensitive, even dangerous, and are also used or handled in controlled environments. The actual size and number of particles per square foot or cubic meter has a lot to do with the systems and installation of a cleanroom, and then there are also rules for the system installation process, with which all manufacturers must comply. Cleanroom protocols are also necessary to protect the environment, product and personnel.
Planning and implementation of cleanroom systems for cleanroom market segments is a process requiring intensive effort. Regulatory standards must be met depending on the type of work performed in the cleanroom. A request for approval must be submitted by the developer and approved by regulatory authorities in the installation process. Service tools, equipment sizing, diagrams showing the location of machines and zoning for air conditioning are some factors to consider in the process of installing the system. These will be important factors to any market segment desiring to stay within regulatory approval.
During the installation of cleanrooms they can be sized in a variety of sizes from small, to mid-range, to larger sized enclosures. They can also be mobile or stationary, depending on the needs of the cleanroom market segments. Types of cleanrooms are independent, hard and soft wall, and portable. Again, the structures can be of any size, and assembled in factories with components that protect against air pollution, noise, ultra-violet radiation, temperature variations, humidity level variations.
Entry into the purified room is a major concern for the cleanroom assembly process, because pollution must be removed before entry, or else it impairs the integrity of the purified room. Dirt, contamination and viruses can be caught in clothing, leather, shoes and hair. This problem can be solved with proper design and protocols. Product flow into and out of the cleanroom envelope must also be properly handled. For a particularly sensitive clean room, an airlock can also be combined so that the samples are brought in by individuals, who are sprayed and cleaned, and wearing specialty clothing they must wear for pollution free rooms.
There are two different kinds of airflow that can be used in a cleanroom designed for one of the cleanroom market segments. Most industries use vertical flow cleanroom installations and some use horizontal flow installations. ULPA or HEPA filters are used in a constant flow through specialized flow systems. By achieving laminar flow, air flow velocity increases and laminar air can remove particles. Laminar flow can be achieved in either a horizontal direction or a vertical direction depending on where the filters are installed. The air becomes clean of particles at least until after your product flow requirements. Effective cleanroom protocols can help your cleanroom facility by maintaining cleanroom conditions and deliver high yields on your products.
Digital Air Control is builder of cleanroom facilities. We offer delivery methods in design-build, plan specification, and design-assist. We offer project costing in firm fixed price, guaranteed maximum pricing (GMP), and cost plus. We can also offer pre-construction services to help formulate your cleanroom design approach. Contact Digital Air Control for your cleanroom needs.
Cleanroom Layouts…
Cleanroom Layouts…
Bill Johnson (Cleanroom Facilities) 2011-10-16 18:19:47
Variety and Layouts of Cleanrooms
Different kinds of cleanroom layouts appear throughout the private sector and industry. Hospitals use a variety of layouts, as they require cleanrooms that are protected against contamination. This, of course, is due to the fact that they deal with disease and medicine. Other industries using cleanrooms can be micro-electronics, chemical control for industrial equipment, drug testing and scientific research. In these areas, the use of clean rooms is necessary, because the risk of dust and other particles from the surrounding environment can obstruct, destroy, or in whatever way compromise important samples.
Cleanroom layouts can be larger or smaller and assembled in factories with components such as aluminum, stainless steel, epoxy coated materials, etc. These components are typically used in cleanrooms to protect against air pollution, noise, ultraviolet radiation and temperature fluctuations. Additional rooms can also be added with no additional contamination. In addition to cleanroom layouts being designed in different sizes from small to mid-range, to much larger, can also be mobile or fixed, depending on the needs of those who are using a clean room for the manipulation of sensitive materials.
Whatever direction users go with for a layout, it is very important for the cleanroom to be an enclosed space and purified, which can then be used to maintain, store and control levels of a wide range of pollutants. The storage of sensitive, even dangerous materials in cleanrooms is addressed in a variety of security measures. Examples of materials range from all components for electronic devices, research and development to the handling of hazardous chemicals used in sectors such as medicine and biological weapon production.
Clean spaces that are ready for entry is a point of interest in the conceptual process and actual construction of cleanroom layouts. Since the contamination is removed first, thereby avoiding compromising the integrity of the treated area, smaller rooms have direct contact with the cleanroom and the products are brought in through this method. An additional chamber is often connected for especially sensitive cleanrooms so that the samples are brought in by people who are sprayed, cleaned and dressed in chemical suits designed specifically to be worn in purified enclosures. There are two types of flow systems that can be utilized in cleanrooms. Ceiling Mounted HEPA or ULPA filtered air filters can blow in a steady airflow through a vertical manner from the ceiling to the floor, called laminar flow. Accentuated by the laminar flow, the air in the cleanroom becomes more unidirectional, and in this way the air is moving in one direction.
The planning and launching of systems with specific cleanroom layouts is a process that requires no small effort. There are standards for public regulation, which must be observed, and depend on the type of work required in the cleanroom. An application for approval must be submitted by the design team and then approved by the regulatory, public authorities for construction of such facilities. Equipment sizing and sketches showing the location of machines and zoning for workers are just some of the factors to be worked in during the process of installing the system. They are critical for any group wishing to remain within governmental regulations for cleanrooms.
The many rules in place for the installation of the cleanroom systems are there because, and manufacturers must comply by these regulations if they intend to produce cleanrooms, the authentic size and amount of particles per cubic meter has a lot to do with the installation of cleanroom systems.
Cleanroom Protocols…
Cleanroom Protocols…
Bill Johnson (Cleanroom Facilities) 2011-10-16 17:56:07
Understanding Cleanroom Protocols Cleanrooms are environments which are typically used in manufacturing, medical, or scientific research in which the amount of environmental pollutants is maintained within acceptable levels. The levels are from ISO Level 1 to ISO Level 9 with Level 1 containing the least contaminants. People are key factors in generating contaminants inside the cleanroom. Physical contaminants include skin cells that flake off, dandruff, clothing fibers, and loose hair. Personal items like paper, pencils, packaging materials, and many other things that shed dust, and even have very tiny particles which can damage the delicate products built and tested in Cleanrooms. In order to minimize the contaminants people bring inside the cleanroom and keep the contaminants within acceptable level, rules and procedures are strictly implemented – known as cleanroom protocols. Gowning is the most common method of keeping the contaminants outside the cleanroom. Proper wearing of cleanroom garments like a gown, bunny suit, or jump suit is effective in making sure that dirt, dusts, pollutants, and others form of contaminants like hair, or dead skin, are not brought inside the cleanroom. Since these pollutants are so tiny and most often microscopic, proper wearing of cleanroom garments should be strictly followed. Some cleanroom protocols include keeping cleanroom shoes inside the facility. If there are no cleanroom shoes in the facility, only use shoe covers. Other cleanroom protocols require hairnets and mask to be properly worn while inside the cleanroom premises. Large mirrors right outside the door of the clean rooms were purposely built to properly check worn hairnets and mask. Part of the cleanroom protocol also requires garments to be handled properly and they must not touch the floor. Good protocols would also prohibit eating or drinking inside the cleanroom. Chewing gum and candy is likewise not allowed. Personal items such as cosmetics, tobacco products, handkerchiefs, tissues, food products, drinks, wooden/mechanical pen/pencils, perfumes, colognes, watches, jewellery, cassette players, phones, beepers, combs, cardboard, or non-cleanroom approved papers are not allowed. Cleanroom garments with pockets should be kept empty. Personal belongings should be kept in lockers or drawers provided in a secure area. Other companies go paperless inside the cleanroom area and transact all office related works directly in computers set-up inside the clean room area. So pens, pencils, and non-cleanroom paper products area prohibited as part of cleanroom protocol.
Another part of the cleanroom protocol is the maintenance of cleanroom garments and shoes. These are periodically sent to laundry facilities for cleaning or disposal single use garments are utilized. In some cases, the company would shoulder the cost of laundry/cleaning of clean room garments/shoes of their employees. As part of cleanroom housekeeping, a selection of cleanroom cleaning materials, equipment, and cleaning agents should be appropriate to the type of cleaning required (i.e., aseptic versus non-aseptic cleanrooms). The company must maintain well documented procedure of keeping contaminants from the clean room. In general, cleanroom protocols are a set of house rules and guidelines, set to maintain the facility’s efficiency and to ensure that it remains compliant with the standard or classification to which it is referred to, while being fully operational.
Cleanroom Wall Systems…
Cleanroom Wall Systems…
Bill Johnson (Cleanroom Facilities) 2011-10-16 17:23:20
The Advantages of Cleanroom Wall Systems
Designing and building a cleanroom used to be a major undertaking, and expensive was the least of it. If you needed anything changed in your cleanroom that meant there could be days, even weeks of downtime. Downtime means lost money, and lost money isn’t good for any company. The solution to these problems would be cleanroom wall systems which allow you to make changes almost on the fly, with little if any interruption to your workflow. Imagine being able to update the layout of your cleanroom without actually putting a dent in the amount of work that was being done.
These convenient and cost-reducing cleanroom wall systems are custom built to the client’s specifications and can be installed much faster than traditional construction. They can also be customized on demand as your needs change, often without interrupting a single work day. These two factors will save a company a tremendous amount of time and money, without creating manufacturing downtime. You can also expect the modular systems to be less less time consuming to building with traditional wall construction, and since they’re built to specification, they’ll have all of the features you need and none of the extraneous features that you don’t.
The practice of using cleanroom wall systems keeps job-site dust down, meaning there’s less contamination for you to clean up before you can put the room to use. The parts are custom manufactured, already cut to size, and ready to set up. That means that the job will go by much faster than a typical construction site, allowing you to get to work faster. It also means that the job site will be cleaner, which is very important when you’re building a clean room. The lack of cutting will mean that very little debris is going to be added to the environment in which you’re building your cleanroom.
Most cleanroom wall systems are designed to be highly customizable. In industries that are changing on a regular basis, this can be a highly desired quality to your custom cleanroom solution. Cleanrooms are typically used in industries such as nano-technology, life sciences and other rapidly changing, technology industries. These changes may make it necessary for you to change the setup of your cleanrooms regularly, which can become expensive for a variety of reasons.
Adding or removing walls and partitions to conventionally built cleanrooms can halt work for days, even weeks. With modular cleanroom wall systems, those same walls can be delivered and installed on site, often without interrupting work for more than a couple of hours, if that. This means that there’s no lost money, and there’s no paying a crew to come in and handle the building and cleaning all over again. The walls can be taken down and moved as your needs change.
Cleanroom wall systems
Cleanroom Construction Delivery Formats…
Cleanroom Construction Delivery Formats…
Bill Johnson (Cleanroom Facilities) 2011-10-16 17:13:36
Getting to Know Cleanroom Construction Delivery Formats Cleanroom construction may entail a lot of tedious work. From designing to planning to construction, you may often find yourself looking for someone that knows and understands the protocol best. You may have to deal with approvals, materials procurement, design specification planning, and so many other things that have to be taken care of. The design and construction of cleanrooms may be a very complex task for different people working for different interests. Good thing that today, along with the great development on cleanroom construction, a lot of cleanroom construction firms offer a total package that will alleviate the many worries of putting up a cleanroom facility. These contractors have personnel that can help you in all areas of designing and planning to construction of the cleanroom. You are guaranteed that these groups are specially formed to work on common goals and conflicts are not likely to happen. It is also important to understand the different cleanroom construction delivery formats that these contractors can offer you. Different cleanroom construction firms offer different cleanroom construction delivery formats. Two of the most popular delivery systems are the plan specification delivery system and the design build delivery system. The plan specification delivery method is where a building owner hires an architect to design plans and specifications for their project. The architect will hire the other design principles to assist in completing the design documents. For cleanrooms, most architects will design and specify a baseline for the project and require a construction team experienced in constructing cleanroom facilities. This method is also known as design assist. The cleanroom contractor will assist the design team with finalizing the cleanroom design and ultimately construct the cleanroom in accordance with the final design. Cleanrooms are extremely complex and extreme attention to detail is required while constructing the cleanroom. Cleanroom protocols are needed and experience is required to implement the cleanroom protocols even before construction begins on the cleanroom envelope. Under the plan specification method budgetary pricing can be establish, but not confirmed until the design and specifications are substantially complete and contractors review and price the construction cost. If the budget is not achieve then value engineering has to be undergone to reduce the construction costs. The next and more common type of cleanroom construction delivery format is the design/build delivery system. The design/build delivery method for a cleanroom project requires a proper creation on the project specification. The contractor should start by presenting a proposal which the owner can easily identify the value they are receiving. With design-build construction delivery a turnkey price can be developed to complete the cleanroom facility. The Owner can know upfront before what the cost of the facility will be. The owner can elect to hire a design build cleanroom contractor under a firm fixed price agreement, a gross maximum price (GMP) agreement, or even a cost plus agreement. Choosing the cleanroom construction delivery format that would suit you best is not difficult. More often than not, each construction firm will offer you only one delivery format. Very rarely do they give you an option on construction delivery format. Your choice of construction firm would depend on the total package they deliver. You should take into account cost, target completion time, specialization on cleanroom controls, and protocols. A wise way to ensure that you get the right firm to work for you is by conducting a simple decision making comparison between your options. The more information you get and the more options you consider the higher the chance that you get the best cleanroom construction firm to work you. Just remember that the cheapest bid is not always the least expensive and the lowest price may not always give you the best value.
Cleanroom Testing…
Cleanroom Testing…
Bill Johnson (Cleanroom Facilities) 2011-10-16 16:49:21
Cleanroom Testing & Balancing
Cleanroom testing & balancing is very important for any facility. When you have a cleanroom, it’s not just enough that it is certified. Depending upon the level of the cleanroom, different kinds of tests will need to be run throughout the day as well as balancing to make sure that all of the levels are maintained at all times so that particles and dust are not entering the cleanroom envelope.
As people enter and exit the cleanroom, the balance can often be disturbed. It is for this reason it’s important to make sure that all employees are going through an air lock before entering the cleanroom. In addition, the use of cleanroom suits, shoe covers and such will help prevent unwanted particles and particulates from entering the room. Since no system is perfect, there are tests that will automatically run in the air to ensure that a certain level is not exceeded.
The National Environmental Balancing Bureau (NEBB) has established Cleanroom Performance Testing (CPT) requirements. Typical cleanroom facilities will require the following to be completely tested and certified:
1.) Airflow Velocity and Uniformity Tests
2.) HEPA Filter Installation Leak Tests
3.) Room Particle Count Tests
4.) Enclosure Pressurization Tests
5.) Temperature and Humidity Uniformity Tests
6.) Sound and Vibration Tests
7.) Light Level and Uniformity Tests
8.) Recovery Tests
9.) Conductivity Tests
10.) Particle Fallout Count Tests
11.) Electrostatic Tests
Typically cleanrooms are certified in accordance with either Federal Standard 209E or International Standards Organization ISO 14644-1. Yes Federal Standard 209E was withdrawn by the US government, but cleanroom operators still continue to operate and certify cleanrooms under 209E standards. The Institute of Environment Sciences and Technology serves as the official Secretariat for the ISO document. ISO 14644-1 was submitted as an American National Standard and adopted as ANSI/IEST/ISO 14644-1:1999 in the United States following the cancellation of FED-STD-209E.
Cleanrooms are typically certified in either an as-built, at-rest or In-Operation condition. The above tests are all done in one of the 3 states. The states are defined by NEBB as below:
As-Built Facility
Cleanroom which is complete and operating, with all services connected and functioning, but which has no production equipment or operating personnel.
At-Rest Facility
Cleanroom which is complete and has production equipment installed and operating, but which has not personnel.
Operating Facility
Cleanroom is in normal operation, including personnel and production equipment.
Cleanroom Testing & Balancing for Pressure
Certain laboratories that are running cleanrooms must not only maintain a clean air level but that the pressure does not change. Cleanroom testing & balancing will ensure that the pressure thresholds are not breached. Often when the pressure changes suddenly it is because of a door, window or vent being opened or closed. If these weren’t meant to open it can mean that the entire room is compromised.
There are various systems that can be placed into the cleanroom to test for pressure and automatically monitor changes. Lower changes can be balanced whereas others may require an alarm or other sound to alert the employees that the pressure has changed too significantly. All of these levels are set based upon the needs of the laboratory or facility and will be different for different fields.
Cleanroom Testing & Balancing for Humidity
While cleanrooms are not designed to omit airborne pathogens and microbes it is supposed to keep dust and other things out of the air. The air passes through state of the art HEPA filters. This ensures that the air circulating in the room is constantly being filtered and cleansed.
Cleanroom testing & balancing is critical to test for humidity. Most of the filters will remove a certain level of humidity. However, if the humidity levels increase too much in the room, the tests will catch the problem and alert staff before it becomes a problem. Especially in regards to cleanrooms for electronics, too much humidity can mean damaged product.
Any level of cleanroom testing & balancing is possible depending upon the facility that you are operating. Testing is an ongoing process as is the balancing. There are different air filters depending upon the balancing of the air quality that is required. HVAC systems and ionizers can be installed to help with the cleanroom testing & balancing as needed. The more systems that are in place, the higher the quality of your cleanroom will be. It’s better to have a higher level system in place than you need rather than compromising your products or results.
Cleanroom Equipment Design…
Cleanroom Equipment Design…
Bill Johnson (Cleanroom Facilities) 2011-07-21 22:05:03
The demand for cleanroom facilities has greatly emerged as we get more involved in the world of science and technology. This facility is needed when executing scientific and medical studies that call for a controlled environment. The need for having a controlled environment is largely because most these scientific fields that utilizes a cleanroom facility works on highly sensitive matters wherein a little deviation on the environmental aspect where the study or research is made, would be greatly impacted. Cleanroom equipment design is very important in getting the cleanroom functionality you need.
is done to make sure that the room is free from airborne molecular contamination, pollutants, or electrostatic fields that may alter the results of the scientific research conducted on the cleanroom. In going through the process of cleanroom equipment design, various considerations have to be taken into account. But before that we have to understand what the cleanroom equipment needed to be placed in a cleanroom. The most typical ones include, the laminar air flow benches, fume hoods, biological safety cabinets pass-throughs, garments cabinet, cross over benches, and air showers. The list even extends up to RFID systems, door interlock systems, bio safety, and bio safety cabinets. The design of all these had to be carefully analyzed in order to get away from having to install or reconstruct the entire cleanroom facility, which unfortunately still happens today.
Cleanroom equipment design
It is important to understand in finding the most optimized cleanroom equipment design you have to remember that these tools or machines operates in an area where air particles are kept clean, and sources of contamination are contained and controlled. Hence it is important that the equipment also has its way of controlling dust particles that it produces or at least it should be easy to handle.
Another thing to consider in cleanroom equipment design is compliance to standards. Building up a cleanroom involves a lot of approvals and design reviews. An authorized body or organization generally conducts reviews and audits cleanroom facilities. Cleanroom construction will not even start without being compliant with the standards set.
Lastly, we want to consider safety, reliability, and maintainability. You don’t want to spend more on maintenance after spending a lot already on the construction. With well thought cleanroom equipment design, savings can also be seen. The quality of materials that goes inside the cleanroom also matters. There are things that should not be found inside an area where electrostatic field should not be generated at all. These things should all be addressed accordingly.
There are many more detailed explanations regarding cleanroom equipment design that you can start reading on. Details for each item that you get to consider should be taken seriously. Cleanrooms are extremely expensive to operate, so careful attention has to be placed on the equipment inside the cleanroom. The success of getting the cleanroom that you need largely depend on how much effort and skill is given on the design and planning activities. Construction firms are available now that can take care of all this. You just have to make sure you know the basics and considerations that should be taken.
Digital Air Control's staff have over 80 years collectively in cleanroom design, who are ready to assist you in preparing your cleanroom. We can help you prepare your equipment matrix and even design and construct the entire facility for you.
A Quick Overview on Cleanroom Equipment Design
Cleanroom Modular Wall Systems…
Cleanroom Modular Wall Systems…
Bill Johnson (Cleanroom Facilities) 2011-07-21 21:52:05
How Cleanroom Modular Wall Systems Can Help You
Cleanroom modular wall systems are an excellent choice for installing your next cleanroom project as they allow you to build in a cleaner environment, have the room built specifically to your plans off site, and allow for faster installation and clean modifications. These features allow for less downtime, lower cost, and are much easier to use your cleanroom as the industry you work in changes. Modular systems allow you to adapt to your changing industry on the fly, and new walls can be added or unneeded walls removed without interrupting your usual work flow.
These cleanroom modular wall systems are designed to the client’s specifications and made to be as convenient as possible. The goal is to deliver the components precision cut to size, ready to assemble and completely clean to your job site. Here, trained professionals will assemble the cleanroom modular wall systems and ensure they’re performing up to standards. The room will be assembled, cleaned and sealed by a team of professional and experienced installers on site. This allows for a much cleaner construction because there is no dust or debris created as there would be with conventional construction.
The nature of cleanroom modular wall systems makes them highly customizable, even on the fly in the middle of a work day. The cleanrooms are designed in such a way that you can easily add or subtract parts, as needed, in order to keep up with a changing industry. Many of the industries that require clean rooms – nano-technology, electronics, life sciences, pharmaceutical and manufacturing – all require businesses to change and adapt at a very rapid pace. Every day that you’re spending adapting your clean room through conventional construction is a day that you can’t work in that room. With modular systems, you can often continue working in the room, even while the room is being modified thanks to the pre-fabricated nature of the walls.
These cleanrooms allow you to update the layout of your room or building as your industry grows and changes, without cutting in to your profit, and while saving you money. Modular cleanroom walls systems are designed so that they can be installed with a minimum of contamination, while the work you do is still happening. They’re also cheaper than conventional construction and allow you to modify and repair on the fly. The rooms are custom manufactured to your plans, so that your room is delivered already cut to size and ready to install, providing for a quick, convenient and clean alternative to conventional construction.
This setup has a variety of advantages over the typical cleanroom construction, with much of it in the money and time you can save. Modular cleanroom wall systems allow you much more flexibility that traditional rooms. These systems are built to the same specifications as a traditionally built clean room, except that there is much less involved in modifying them, and there’s last debris added to the environment during construction. This can help keep your clean room clean, and cut down on any potential negative environmental impact.
Cleanroom Lighting Systems…
Cleanroom Lighting Systems…
Bill Johnson (Cleanroom Facilities) 2011-07-21 21:36:48
Cleanroom Lighting Systems
If you’ve got a cleanroom, then you’ll need to light the space. Since you will need to be concerned with the way the light source maintains a seal and eliminates additional particles into the air, a standard lighting system won’t be sufficient. You will need to look for cleanroom lighting systems which are custom designed for cleanrooms to maintain the integrity of the air that you are steadily filtering.
Cleanroom Lighting Systems for the Ceiling Cleanroom lighting systems
Many of the systems are designed to fit specifically into a standard ceiling grid. If you’ve got a unique ceiling, let us know and we will most likely have a solution for you. Depending upon the level of your cleanroom, there will be certain requirements imposed by your certification to determine what kind of lighting you’ll need. There are some systems that allow air to penetrate and circulate through the lighting and others that are completely sealed so that contaminants cannot enter.
Gaskets are used in all of the cleanroom lighting systems. This ensures that the lighting is flush against the ceiling or wall so that particles cannot lodge themselves into the structure. Particles from a light are often reasons for particles to exist in a cleanroom. This will also prevent a cleanroom from being recertified.
Cleanroom Lighting Systems Throughout the Room
Especially when you are dealing with electronics and small objects, a cleanroom lighting system in the ceiling may not be sufficient. You will probably need lighting for the tasks being performed at each workstation so that you and your employees can see what you are doing.
Again, you can’t put a typical lamp at the table so you’ll need to consider options that will keep the air free of particles. Your choices? You’ve got several but you need to get them from a company who sells cleanroom lighting systems, not from any random store. Many of the systems are designed to allow air to flow through the light so that the air quality is maintained even within the lenses of the light. These can be desktop units or tear drops that hang above the workstation.
Working with a company that specializes in cleanroom lighting systems will ensure that you get the right products for your facility. You’ll need to have a well-lit work area and because of the sensitivity of your room to dust and particles, a regular light that you can buy in an office store won’t work. Anything that can trap dust inside is a breeding ground for more dust and will corrupt you cleanroom. You will get all of the lighting that you need and maintain the integrity of the projects that you are working on.
Cleanroom Classification Levels…
Cleanroom Classification Levels…
Bill Johnson (Cleanroom Facilities) 2011-07-20 21:59:46
Cleanroom Classification Levels
US Federal Standard 209E Particle Levels
|
Class |
Maximum Particles per Cubic Foot of Air |
ISO Comparison |
||||
|
≥0.1 µm |
≥0.2 µm |
≥0.3 µm |
≥0.5 µm |
≥5 µm |
||
|
1 |
35 |
7 |
3 |
1 |
|
ISO 3 |
|
10 |
350 |
75 |
30 |
10 |
|
ISO 4 |
|
100 |
|
750 |
300 |
100 |
|
ISO 5 |
|
1,000 |
|
|
|
1,000 |
7 |
ISO 6 |
|
10,0000 |
|
|
|
10,000 |
70 |
ISO 7 |
|
100,000 |
|
|
|
100,000 |
700 |
ISO 8 |
Institute of Environmental Sciences and Technology (IEST)
ISO Standard 14644-1 International Standard for Cleanrooms
|
Class |
Maximum Particles per Cubic Meter of Air |
US Fed Std 209E Comparison |
|||||
|
≥0.1 µm |
≥0.2 µm |
≥0.3 µm |
≥0.5 µm |
≥1 µm |
≥5 µm |
||
|
ISO 1 |
10 |
2 |
|
|
|
|
|
|
ISO 2 |
100 |
24 |
10 |
4 |
|
|
|
|
ISO 3 |
1,000 |
237 |
102 |
35 |
8 |
|
Class 1 |
|
ISO 4 |
10,000 |
2,370 |
1,020 |
352 |
83 |
|
Class 10 |
|
ISO 5 |
100,000 |
23,700 |
10,200 |
3,520 |
832 |
29 |
Class 100 |
|
ISO 6 |
1,000,000 |
237,000 |
102,000 |
35,200 |
8,320 |
293 |
Class 1,000 |
|
ISO 7 |
|
|
|
352,000 |
83,200 |
2,930 |
Class 10,000 |
|
ISO 8 |
|
|
|
3,520,000 |
832,000 |
29,300 |
Class 100,000 |
Biosafety Levels are defined by the Centers for Disease Control (CDC) and the National Institutes of Health. There are basically 4 different levels and each different type of facility handles different types of infectious agents. Each Biosafety level accounts for operations that can be performed, known and suspected routes of transmission and Laboratory function.
Biosafety Level 1 (BSL-1)
BSL-1 is the lowest level because of the materials being handled. BSL-1 levels are appropriate for facilities that handle and work with defined and characterized strains of viable organisms that will not cause a disease reaction in healthy adult humans. Level 1 precautions are based on standard microbial practices with any special primary or secondary barriers. BSL-1 criteria are mainly for undergraduate and secondary educations laboratories.
Biosafety Level 2 (BSL-2)
BSL-2 are mainly facilities that handle a broad range of indigenous moderate-risk agents known to cause disease in humans. BSL-2 precautions are necessary when working with human blood, bodily fluids, or tissues where an infectious agent is unknown to be in the sample. Primary hazards in BSL-2 labs are in injection and ingestion.
Biosafety Level 3 (BSL-3)
BSL-3 applies to facilities that handle indigenous or exotic agents with the potential for lethal infection and aerosol transmission. The hazards in a BSL-3 lab are inhalation, autoinoculation and ingestion. BSL-3 labs precautions place an emphasis on primary and secondary barriers. For primary protection, all laboratory actions shall be performed in a biological safety cabinet or other enclosed equipment. Secondary protections include controlled access and very specialized ventilation systems in the lab.
Biosafety Level 4 (BSL-4)
BSL-4 lab precautions are required for facilities that work with dangerous and exotic agents with a high risk of causing life-threatening diseases, no known vaccine or therapy to cure and the possibility of aerosol transmission. BSL-4 samples required complete isolation. Full bodied air supplied positive pressure safety suits for personnel protection or Class III biological safety cabinets are required when processing level 4 agents. Waste management systems, isolated facilities and specialized ventilation are required in BSL-4 labs.
European Standards
Grade |
Air Changes per Hour |
|
Grade A |
480-600 |
|
Grade B |
35-70 |
|
Grade C |
20 |
|
Grade D |
20 |
Cleanroom Construction…
Cleanroom Construction…
Bill Johnson (Cleanroom Facilities) 2011-07-20 19:40:32
Cleanroom Construction Protocols and Requirements
Every construction project can sometimes use dangerous and unreliable materials that can harm humans. That is why a thorough analysis and study prior to construction is made to ensure that these possibilities are taken care of. This is even more significant for cleanroom construction since a lot of considerations have to be considered to guarantee quality and efficiency of the cleanroom.
In planning for cleanroom construction, you start with the type of design you want to implement on your cleanroom. There are lots of different types of cleanrooms such as hard-wall, soft-wall, portable, or self-contained cleanrooms. They can either be rigid and permanent or small and portable. These modular enclosures are usually assembled in the manufacturing of plants and use materials that do not attract air contaminants or shed particles. They also make use of materials that guard the room from temperature variance, ultraviolet lights, and excessive noise.
Airflow is also another factor that has to be thoroughly studied in cleanroom construction. There are two air flow principles that can be applied to cleanrooms. First is the laminar air flow, which makes use of a system that constantly blows HEPA or ULPA filtered air stream downward through ceiling mounted terminal filter units. Certainly laminar flow is preferred in many cleanroom settings. Turbulent air flow on the other hand is a system that makes use of velocity HEPA or ULPA filters and air flow hoods that jet stream the filtered air on different directions, because there is not 100% filter coverage or devices to create a laminar flow in the cleanroom.
Entry rooms or gowning rooms require special attention in cleanroom construction. Gowning rooms need to be positive pressure with the areas outside the cleanroom area, but typically need to negative pressure to the actual cleanroom area. This keeps particles from the gowning process and particles outside the cleanroom from making it in the clean zones. The gowning rooms are where shoes and clothing are kept to ensure that no dirt and dust get into the room and anyone that has to enter a cleanroom needs to go through an airlock chamber and sometimes an air shower to avoid bringing in particles on the staff’s gowns.
The planning and constructing a cleanroom can be a tedious job. Rigid protocols need to be followed in order minimize contamination inside the cleanroom area. The lower the particle count inside the facility the more rigid the construction protocol becomes. The chart below shows the cleanroom classifications according to the various standards.
Cleanroom Classifications
|
Federal Standard 209E |
ISO Standard 14644-1 |
European Standard |
Biosafety Levels |
|
Class 1 |
ISO 3 |
Grade A |
Biosafety Level BSL-1 |
|
Class 10 |
ISO 4 |
Grade B |
Biosafety Level BSL-2 |
|
Class 100 |
ISO 5 |
Grade C |
Biosafety Level BSL-3 |
|
Class 1,000 |
ISO 6 |
Grade D |
Biosafety Level BSL-4 |
|
Class 10,000 |
ISO 7 |
||
|
Class 100,000 |
ISO 8 |
See More Information on Cleanroom Construction Levels
For a pharmaceutical facility with active ingredients, regulatory bodies have to validate your plan before design and construction can start. You have to get their approval in order to proceed with your cleanroom construction in addition to the local municipalities’ approval for construction. There are pre-set standards that these regulatory bodies will look into. Some of them are the sizing of equipment, flow diagrams that includes placement of the equipment and people and utilities to service. These factors will be checked according to the type of work intended to be done on the cleanroom. Most cleanroom construction is intended mostly for pharmaceutical, microelectronics, nanotechnology and biotechnology industries. These industries require a controlled environment because dust and pollutant particles can unfavorably affect product during the manufacturing process.
Overall, cleanroom construction requires a lot of planning and designing analysis. There are lots of construction firms specializing on cleanroom constructions that you can work with. The World Wide Web is one great avenue that can provide you a list of options that you can entrust construction of your cleanroom to. You may use the above discussed items as a starter on what needs to be taken into account.
Digital Air Control’s staff is extremely familiar with cleanroom design and construction. Our staff has collectively nearly 80 years of design, installation, and overseeing cleanroom construction. In need of a cleanroom facility, please prepare your questions and give us a call.
Cleanroom Climate Control…
Cleanroom Climate Control…
Bill Johnson (Cleanroom Facilities) 2011-06-19 14:47:58
Cleanroom Elements and Climate Control
There are two types of airflow systems that can be used in cleanroom climate control. Primary cleanroom air is recirculated through the room by ceiling mounted HEPA or ULPA filters. The primary air can be through fan filter modules or ducted primary recirculation fans directly connected to ceiling mount HEPA terminal units. The air is usually returned back through either low side wall returns or raised access flooring. The air pushes through the room from the ceiling. The lower the number of particles allowed in the cleanroom, the higher the number of HEPA or ULPA filters required, thusly the higher the airflow or air changes in the clean room.
Laminar flow in clean rooms is optimal with a raised access floor which allows the air to flow through the room on straight lines. Accentuated by the laminar flow of air into the cleanroom the air in the room is continually flowing through the room. Multiple industries use cleanrooms: hospitals use them because they require spaces that are protected against contamination, thus enabling practitioners to work with medicine and viruses in a safe space; sectors that test industrial equipment, drug testing and scientific research are also amongst those in need of cleanrooms. The use of cleanrooms is necessary because the risk of dust and other particles in the environment can interfere with, destroy, or otherwise compromise samples and or products significantly.
Cleanrooms are assembled in factories with components such as non particle shedding materials. These components are typically used in cleanrooms to enhance cleanroom climate control. Cleanrooms normally have temperature and humidity control in the cleanroom space, so materials that can form a vapor barrier are typically used. Epoxy paints, foil backed drywall, will typically the perimeter of the cleanroom zone. When drywall is used, the drywall is covered with aluminum lining material to keep from the drywall being damaged.
In addition, cleanrooms can be designed in various sizes, from small to medium range to much greater, but may also be mobile or fixed, depending on the needs of those using the clean room and what materials they’ll be working with. The products being constructed inside the clean room area often dictate the size, and materials used to construct the clean room envelope.
Whatever direction the users agree on for a design, it is very important for these spaces to be cleaned and closed rooms, with functioning cleanroom climate control, which can then be used to maintain, preserve and control the amount of a wide range of pollutants. Examples of materials that might be found in a cleanroom are computer hard drives, or hazardous chemicals that must not be exposed to the outside world, not only for the integrity of the sample, but also for the safety of public health.
Clean space entrances that are ready for use are a milestone in the design process and the actual construction of a purified enclosure. Because pollution must be eliminated first, thus avoiding compromising the integrity of the treated area, small rooms are in direct contact with the cleanroom, and the products are brought in through this mode. The rooms help form a barrier for the cleanroom to outside ambient. The barrier rooms often are areas where materials entering the cleanroom are wiped and cleaned of particles before entering the cleanroom area. The additional rooms also help support the cleanroom climate control. There is often another additional room with which people must be sprayed, cleaned, and then suited up in specially designed suits meant both to protect the wearer from whatever hazardous chemicals they may be handling in the cleanroom, but also to protect the cleanroom from any pollutants brought in by the people themselves. Pollutants can be carried in by people through their hair, shoes or clothing. Humans shed dead skin on a continual basis and these particles are controlled by personnel wearing cleanroom suits, gloves, hairnets, shoe booties and maintaining hygiene by washing up before suiting up.
There are many rules in place for the installation of cleanroom systems, and cleanroom installers must comply with these cleanroom protocols when they are constructing a cleanroom area. Planning and construction of just the cleanroom climate control is a process that requires much effort as there are building codes and energy recovery standards which must be observed. By controlling temperature and humidity in clean areas, the facilities are terribly inefficient in energy management. With building officials focusing on energy management these days, new requirements are being put in place for controlling the energy in the cleanroom areas.
The only thing that will trump energy management is personnel protection inside the cleanroom areas. When certain chemicals or hazards are presented in the cleanroom area, there are typically high levels of exhaust air. The exhaust temperature can be reclaimed through energy recovery means as long the chemicals or toxins do not damage the energy recovery materials. As building codes advance, designers and owners will have to have a higher knowledge base to designing cleanroom facilities.
Digital Air Control’s staff has been designing and building cleanroom facilities for over 20 years. Many changes have come to cleanrooms since the early 1990’s and cleanrooms will continue to change. Contact Digital Air Control’s staff to assist with your cleanroom needs.
Cleanroom Certification…
Cleanroom Certification…
Bill Johnson (Cleanroom Facilities) 2011-06-05 16:43:41
Cleanroom Certification
Cleanroom certification is a critical part to having a cleanroom as part of your facility. Whether you have a cleanroom for optics, electronics, medical testing or another reason, it’s important that you have the facility certified so that you are providing the level of cleanliness in the air that you think you are providing. The certifications will also help to ensure that everyone else can trust your products and results.
Levels of Cleanroom Certification
Ultimately, the cleanliness level of your cleanroom may be different than someone else’s cleanroom. Everything is based upon a number of particulates in the air. The lower the number of particles in the air, the lower the cleanliness level of the cleanroom. For example, under Federal Standard 209E, a class 1 cleanroom has 1 maximum 0.5 micron or larger particle in one cubic foot of air. When you are dealing with nanotechnology, the smallest amount of dust can ruin a product. Others that have a larger product interface may not require such a low percentage. Pharmaceutical cleanrooms are concerned about particles, but they typical can have a higher number of particles in the airstream. Pharmaceutical cleanrooms require great strides to insure the particles that are there are dead particles and not live micro-organisms.
Cleanroom certification will establish the level of the cleanroom and based on cleanliness levels, cleanroom protocols will need to be established. Employees working in the cleanroom will have to be trained as to what is required of them as they enter the facility. Some cleanrooms will require the use of a full cleanroom suit, shoe covers, and headwear. Others will simply require a smock, bouffant hat and shoe covers. The products that go into a cleanroom will also determined the cleanroom classification. Pencils and other products with natural fibers that could cause small particles to become airborne will likely be omitted from the room. A special type of cleanroom paper is used inside cleanroom envelopes. The Cleanroom classification also dictates the gowning levels inside the cleanroom, so cleanroom protocols will need to be developed based on the type of facility, products manufactured, and cleanroom level.
Testing for Cleanroom Certifications
The cleanroom certification will typically test the following points based on a test grid:
- Temperature reading each point
- Humidity reading each point
- Particle counts per cubic foot of air each point
- Air Balance
- Air flow testing for HEPA filtration
- Airflow testing for return air
- Water Balance for air handling units
There are various tests that will go into a cleanroom certification. They will check the functions of the air lock (if applicable) to make sure that it is functioning properly. This will include the air shower if your facility has one.
There is an instrument, called a particle counter, used that will count the number of particles per cubic foot of air to determine the concentration of the airborne particles in the air. The particle counter will be used based on a test grid throughout the entire cleanroom facility. The test grid is established based on Federal Standard 209E/ ISO 14644. There are user defined points agreed to between the cleanroom owner and builder. For instance, the height of the particle counter cup is defined by contract. Typically the height is determined based on product flow height through the facility. If the product flows through the facility at 36" Above Finished Floor (typical tabletop height), then the particle counter cup should be placed a 36" AFF for testing. Some cleanrooms are certified at 6’-0" above the finished floor, but 36" is more typical.
Typically cleanrooms are certified at least once a year and are typically recertified each year thereafter. Some customer choose to have a active system of particle measuring system, so they can know how the performance of the cleanroom facility on an ongoing basis. Particle measuring systems are typically a centralized system of particle measuring locations. Each location ties into a pump that transfer air for individual points located throughout the facility back to a centralized particle counter and the particle counter will run rotate through the points to particle levels on a routine basis.
Renewal of Cleanroom Certification
The type of facility that you have will dictate how often you need cleanroom certification conducted. If you are a laboratory and are trying to get FDA approval, you may need to have your cleanroom certified on a regular basis. Otherwise, the standard operating procedure is to have the cleanroom certified annually. Once you build a cleanroom, the company who builds it for you will set up the first certification to prove the cleanroom performs as required. After that, the company that certifies the cleanroom will schedule as necessary based on your input.
Digital Air Control can perform air and water balancing, cleanroom performance testing and even certify your facility in accordance with Federal Standard 209-E or ISO 14644. Contact us for a quotation.
Cleanroom Design and Construction…
Cleanroom Design and Construction…
Bill Johnson (Cleanroom Facilities) 2011-06-05 14:42:43
Design, Construction, and Purposes of Clean Rooms
A cleanroom is an area that has tight controls on temperature, humidity and particles in the air. It is a room where sensitive materials, or even hazardous ones, are used and handled. These materials can include such equipment to manufacture semiconductors, medical devices, biotechnology, flat panel displays, hard drives, MEMS devices, or the handling of hazardous chemicals used in medicine or weaponry. The actual size and number of particles per cubic meter has much to do with the planning and implementation of a clean room. There are also regulations to cleanroom design and construction that all builders must adhere to. There are Federal and International classifications of cleanroom standards depending on their purpose and also depending on the industry they are being used in.
There are two different air flow types that can be used in cleanroom design and construction. Ceiling Mounted ULPA or HEPA Filters are utilized with air being circulated with direct duct connections to each filter and the air is pushed through the room. Dust and particles can have a negative effect on product evaluation and testing. The scientific research industry, the microelectronics industry and facilities that test pharmaceuticals are companies that require cleanroom design and construction. Cleanrooms are technology advanced facilities and require a skilled company to design and construct a cleanroom facility.
Particles of dirt, contamination and viruses can be caught in clothing, leather, footwear, and even hair. Therefore, the entrance of the cleanroom is a major concern in cleanroom design and construction, as impurities must be removed before entering, or risk compromising the integrity of the clean enclosure. In order to address this concern, small rooms are directly connected to the clean room, and products are brought in this way. For a particularly sensitive clean room, an airlock or airshower might be connected so that individuals are sprayed with high velocity air before entering, with the same individuals often wearing a special suit designed to be worn inside such an enclosure. Air showers where extremely popular in ultra clean facilities, but the popularity has diminished over time.
The planning and implementation of cleanroom design and construction is an intensive process. For Pharmaceutical cleanroom facilities, approval must be requested by the owner and approved by the relevant regulatory authorities during the process of implementation. Service tools, the sizing of equipment, flow charts that show the location of machines, and air conditioning zoning are just a few of the factors to consider when designing a cleanroom and seeking regulatory approval. Regulatory standards must be met depending on the type of work conducted in the clean room.
Cleanroom design and construction can encompass smaller or larger rooms. These rooms might be movable or stationary. A few of the different design types are autonomous, portable, hard wall and soft wall. Modular cleanroom structures come in all sizes and are assembled in factories using components that protect against airborne contaminants, noise, ultraviolet light and temperature variation. Soft wall cleanrooms are popular for pilot facilities or temporary areas. Modular Cleanrooms areas allow for ease of walls to be relocated for new tool installations. We have seen cleanroom facilities that were reconfigured on average every two years due to tool change outs and reconfigurations because technology was advancing at a ultra fast pace.
An Overview on Cleanroom Cost Estimation Analysis…
An Overview on Cleanroom Cost Estimation Analysis…
Bill Johnson (Cleanroom Facilities) 2011-06-03 16:28:50
An Overview on Cleanroom Cost Estimation Analysis
The fast pace of innovations and modernizations on science and technology calls for a demand for better and greater cleanroom designs. Cleanrooms are controlled areas intended for scientific and laboratory works where environmental conditions are maintained with minimal amount of particles, temperature and humidity tight tolerances. These facilities have controlled the level of allowable pollutants or contaminants that are usually defined in terms of a particle size and the number of particles per cubic meter. With these delicate requirements, it is only expected that cost to construct these facilities has to be carefully done, since it involves a large amount of capital and operational investment. Hence, cleanroom cost estimation analysis has to be part of the constructions’ feasibility study.
The purpose of doing cleanroom cost estimation analysis is to minimize construction costs, shorten construction time while taking into consideration efficiency and operational costs that would be realized once cleanroom construction is completed and running. Estimations are put together through considering a lot of factors. Some of these factors include the cleanroom class, cleanroom area, modular walls, end use of equipment, type of industry, air return and gown-up room. Basically cleanrooms are there to protect the product from an environment, so particle levels, temperature, humidity are controlled. So cleanrooms are constructed to protect the people in the facility from the product.
Cleanroom class refers to the cleanroom’s classification in accordance to the different standards set by ISO, Federal Standard 209E and other standardizing bodies. This is determined by the size and number of particles allowed per volume of air. In doing cleanroom cost estimation analysis, it is important to define which standard it will be referred to. The lesser the number of particles permitted per volume of air, the more expensive the cost of cleanroom construction gets.
Another factor to be considered on cleanroom cost estimation analysis is the cleanroom area. Obviously, the larger the floor area, the higher the construction cost. Also, here we take into account the flooring type. The owner needs to define whether they prefer to have a vinyl or raised access flooring. Typically raised access floorings are preferred by those who want to increase room performance. Raised floors allow the air to flow through the cleanroom in a laminar direction, increasing performance.
Air return is also another factor that may affect cleanroom cost estimation analysis. Air return is the system on how air motion is controlled inside a cleanroom. The air flow system typically pushes air through ceiling mounted HEPA Filters and air is returned through low side walls return air cavities or through raised floor panels. Raised floor panel air return usually costs more as compared to the low side wall air flow system.
Last consideration that has to be noted on clean room cost estimation analysis is the gowning room. Gowning rooms are the area where people suit up before entering the cleanroom. Some facilities use an air shower. Air Showers are a small area where filtered air blows to the person before entering the actual cleanroom. Most cleanrooms have a dedicated area for gowning. This allows a specific isolated area for cleanroom personnel to prepare to enter the cleanroom by gowning up. This is done to ensure that no pollutants are carried on the laboratory gowns worn by the person entering the cleanroom.
Overall, the cost of a cleanroom facility is determined by the function it is supposed to serve and the standard it is referred to. Performing cleanroom cost estimation analysis allows the owner to weigh in their options and make a just decision to materialize a reasonable yet efficient construction of a cleanroom.
Cleanrooms are built around the equipment inside the cleanroom facility. It is important to develop an owner’s equipment matrix for the cleanroom facility. Every service required for the process equipment needs to be added to the matrix from Deionized water, compressed air, nitrogen, electrical power, process vacuum, exhaust, process cooling water, and on. The matrix is where the cleanroom designers will put together the total requirements for the cleanroom facility. The equipment matrix can also have diversities applied, as some equipment uses the process infrastructures intermittently.
When developing a cleanroom facility cost, always work with people who are familiar with cleanroom construction. Cleanrooms are complex facilities and require an experienced knowledge base on how to put together budgeting and construction of the facility. Cleanrooms are so specialized it is best to use a cleanroom design builder to work with you to complete your facility.
The Benefits of Cleanroom Design Build Construction…
The Benefits of Cleanroom Design Build Construction…
Bill Johnson (Cleanroom Facilities) 2011-05-10 19:11:08
Cleanroom design build has numerous benefits for the facility owner. It is a method where one company is in control of all the processes from designing to construction. This is preferable instead of getting various entities on the job and the owner acts as the go between to ensure that all stages in the cleanroom design build are completed. In essence, the facility owner’s presence can be focused on running their existing operation, while a team is focusing on completing the tasks required for installing a new facility. The contracting company will take on responsibility of coordinating the activities to ensure that the designer’s concept is followed and all workers from the engineer to the construction staff are working on schedule. They will come up with the drawings, specifications and construct it.
By focusing the facility team through one source, the team work guarantees that all sections of the cleanroom design build are handled with care and the project comes out complete. Typically a design build facility will have some performance based requirements, like temperature, humidity, particulate levels, system performance, etc. Performance based contracting works particularly well with cleanroom facilities. Cleanrooms for all types of industries from pharmaceutical to Nanotechnology to Microelectronic to Government will also have a performance requirement at the end of the job.
When an owner hires multiple companies the performance aspect is hard to tie to one entities responsibility. Therefore with cleanroom design build performance based contracts the responsibility rests with one entity. The owner has one source to look to with any defiencies in performance.
The facility owner can brief the team about the needs and the type of laboratory required, the team will have the same ideas and this promotes the success of the project. If the facility owner is working with several companies and has the stages of construction divided amongst them, the coordination may lack and the project delivery will be effected.
In addition, the cleanroom team will follow the time plan laid out during the team’s meeting. Every section of the advanced technology facility designing process will have its timed duration. The team players will forecast the time they can take on the project and this will avoid any hiccups that may delay the cleanroom construction. In case of delays, the team will sort the situation out to get the process back on track, unlike with multiple different companies. The owner takes a risk to make sure coordination is done extremely well.
A design build project manager will take control of the stages and oversee the reports from different sections of the design. The construction company will ensure that it has the right machines and equipment to meet the standards of cleanroom design build and needs of the facility owner. Otherwise the facility owner will be required to maintain the coordination of their team members.
Additionally, the facility owner will have reduced cost through design build construction. Dealing with a number of entities might give the facility owner untold expenses from the monitoring to the cost quotes each company will present. However, when all costs are consolidated into one company, the price reduces remarkably. Another bonus is the facility owner is able to control the risks that may crop up. This is better than handling a number of designers, engineers and builders all in different geographical areas and with different objectives in the project.
Digital Air Control is a design builder of cleanroom facilities. Our staff of cleanroom professionals have been working as a team for constructing cleanroom facilities since 1988. Contact us for any questions you may have on constructing a cleanroom facility.
Nanotechnology Cleanroom Facilities…
Nanotechnology Cleanroom Facilities…
Bill Johnson (Cleanroom Facilities) 2011-04-13 12:40:01
Our staff at Digital Air Control have been involved in numerous Nanotechnology projects. Nanotechnology is a broad field and has many applications, some are incubator facilities that will produce numerous other companies.