Cleanrooms Build Process is improved over time. From the learnings of more than a hundred designs that we’ve done for different clients, we’ve developed a lot of general templates in order to build our Mobile Compounding Cleanroom. One of the things that we’re putting in our designs and plans is the general room requirements. That includes how many CFM are required to run a single room at ISO class 7 requirements. We also calculate how many cubic feet of air has to be exhausted so the installed HVAC system will be enough to maintain the desired levels.
In most of these jobs, we’re starting with something that is very close to what our client’s final requirements are, we develop an initial model and go through your specific applications and needs. By the end of the design stage, we’re providing our clients with our detailed design, construction set, and requirements spec sheet.
We can turn over these detailed designs to your equipment certifier that’s going to be coming in so they can do a lot of the planning and anticipation of what their overall needs are going to be and make the certification process much more streamlined upon implementation of the equipment.
In the detailed design, we’re supplying measured-out elevations so that we can make sure that the outlets are at the right height, so our clients can see exactly where the electrical panel is. So if anything needs to be tweaked at this point, we can surely accommodate all changes here prior to the manufacturing schedule of the equipment.
After we develop our final conceptual design and our clients sign it off, we bring in a shipping container into our shop and start the modification process.
Cleanrooms Build Process
The general build process starts with a 40-foot shipping container in our shop, we reinforce the panels and undercarriage with aluminum stud construction. Next, we set up and position the air handling systems that are going in. What we’re doing next are the in-wall components as we are prepping the container for insulation.
We choose shipping containers to manufacture these mobile units because of their soundness and their structural integrity. We definitely build these things to be a permanent solution that is also moveable.
As soon as the applied insulation sets, we continue executing our design work by putting a substructure of 3/4 inch fire-treated plywood, as fire-treated plywood increases the overall fire safety rating of the equipment. We then laminate the plywood, which makes the overall finish much smoother and much more cleanable. We also cover the floor with a single sheet of linoleum flooring to reduce the number of seams.
We then build the rooms with all the HVAC specs and in accordance with the size and spec from the design we’ve initially developed. Later we install and set up all equipment that needs to go in according to the conceptual design. If we’ve specified equipment that our clients already have on-site, we’ll install that at a later point.
When the MCC arrives on site, the only things left to do are to run up to a typical water supply, water drain, and electricity. We can make these totally self-sufficient, as we can install a power generator, water supply holding tank, and we can install waste holding tank. That way the whole unit can be run independently of building facilities.
We can surely configure our MCC to be able to run without being plugged into any Power and Water supply from the main building, however, for the most efficient workflow, we recommend being connected to the main building lines.
The whole process from developing the conceptual design all the way up to final delivery and install is intended to last less than 5 months.
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