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Modular Cleanroom Installation Process: What to Expect in 5 Steps
Created on 01.26
Choosing a modular cleanroom over traditional construction offers significant advantages in speed and flexibility, but understanding the installation process is key to ensuring a smooth project. Here's what you can expect in five clear steps when working with a professional modular cleanroom manufacturer.
Step 1: Site Assessment and Preparation (1-2 Weeks)
What Happens:
Manufacturer Visit: A project engineer visits your facility to assess the designated space. They verify critical parameters such as ceiling height, floor load capacity, access points for large components, and the location of existing utilities (power, data, compressed air, etc.).
Foundation Check: The floor is evaluated for levelness, smoothness, and strength. Any unevenness outside the tolerance (typically ±3mm over 3 meters) must be addressed before installation begins.
Utility Planning: Exact points for electrical drops, data ports, and any process piping are finalized and marked.
Pre-Installation Checklist: You receive a clear list of site requirements to complete, such as ensuring the area is cleared, climate control is operational in the building, and necessary permits are in hand.
Your Role:
Provide full access to the site for assessment.
Complete any recommended floor leveling or structural reinforcements.
Ensure all utilities are stubbed out to the agreed-upon locations.
Step 2: Component Delivery and Staging (1-2 Days)
What Happens:
Organized Delivery: All pre-fabricated components—wall panels (metal, FRP, or glass), structural frames, ceiling grids, fan filter units (FFUs), doors, windows, and gaskets—arrive on schedule in clearly labeled packaging.
Protected Staging: Materials are carefully unloaded and staged in a nearby, protected area, often in the reverse order of installation to maximize workflow efficiency.
Inventory Verification: The installation team cross-checks the shipment against the packing list to ensure all parts are present and undamaged before work commences.
Your Role:
Designate a secure, accessible staging area near the installation site.
· Coordinate with building management for loading dock access and freight elevator scheduling if needed.
Step 3: Structural Frame and Wall Panel Assembly (3-7 Days)
What Happens:
Frame Erection: The lightweight but robust aluminum or steel frame system is assembled first. This creates the skeleton of the cleanroom. Laser levels ensure perfect plumb and alignment.
Panel Installation: Wall and ceiling panels are meticulously installed onto the frame. Interlocking panels and cam-lock mechanisms ensure a tight, seamless fit. Any view windows or pre-cut service ports are integrated at this stage.
Airtight Sealing: All joints, seams, and penetrations are sealed with specialized non-shedding gaskets and silicone to achieve the required airtight integrity for pressure control.
Your Role:
Limit general foot traffic in the adjacent area for safety and to keep the site clean.
Be available for any immediate questions regarding component placement or unforeseen site conditions.
Step 4: Integration of Critical Systems (3-5 Days)
What Happens:
Ceiling Grid & FFU Installation: The T-grid ceiling is suspended, and HEPA/ULPA Fan Filter Units (FFUs) or lights are dropped into place. Units are connected to power.
HVAC Balancing (if applicable): For systems with external HVAC, ductwork is connected, and airflow is balanced to meet the specified air change per hour (ACH) rates and pressure differentials between rooms.
Electrical & Controls: Electricians wire lighting, controls, and monitoring sensors (for pressure, temperature, humidity). Control panels are mounted and tested.
Flooring Installation: Raised access floors or welded sheet vinyl flooring is installed, with coving up the walls for easy cleaning.
Your Role:
Facilitate coordination between the modular installer and your facility's electrician or HVAC technician if required.
Approve any minor field adjustments that may be proposed to optimize system performance.
Step 5: Final Testing, Certification, and Handover (2-4 Days)
What Happens:
System Commissioning: All systems are powered on and run through operational tests. This includes verifying fan speeds, lighting levels, alarm functions, and control system interfaces.
Performance Certification: A certified technician performs key tests to verify the cleanroom meets its specified ISO classification:
Airborne Particle Counts: To validate cleanliness class.
Airflow Velocity & Uniformity: Tests at the filter face and within the room.
Room Pressure Differential: Verifies proper cascade between zones.
Leak Testing: Of filters and room envelope.
Documentation Package: You receive a comprehensive handover package, including as-built drawings, equipment manuals, filter certificates, and the final test reports.
Cleanroom Orientation: The installation team walks your personnel through the basic operation of lights, controls, and safety features, and reviews proper gowning and entry procedures.
Your Role:
Participate in the final walkthrough and orientation.
Review and file the certification documents for your quality management system.
Officially accept the completed installation.
Why a Professional Manufacturer Makes the Difference
A streamlined 5-step process is only possible with an experienced manufacturer. They provide a single point of responsibility, from detailed upfront engineering that minimizes on-site surprises, to using trained installation crews familiar with their specific components. This integrated approach is what turns the promise of "fast installation" into a predictable, high-quality reality, getting your critical production or research space operational in weeks, not months.
Ready to plan your installation timeline? Contact us for a detailed project schedule and site preparation guide tailored to your specific modular cleanroom design.
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