The next generation of modular cleanrooms

After several years of building modular cleanrooms, Clean Modules Ltd has now developed the next generation of modular cleanrooms. Clean Modules Ltd specialises in constructing bespoke modular cleanrooms and as a result, not two cleanrooms are the same. This diversity has allowed Clean Modules Ltd to continuously develop their modular cleanroom concept.

Modular cleanrooms can be used for a wide range of applications: They can provide both temporary and permanent facilities; they can be used to extend an existing facility, to provide a new stand-alone facility or as a mobile unit. Some of Clean Modules Ltd’s modules have literally been sent to the far corners of the globe.

Modular cleanrooms are a fast and convenient method of providing cleanroom facilities and can be fitted, commissioned and validated away from the site, then quickly installed and put into use. This was the main reason for Clean Modules Ltd to construct a modular cleanroom facility for the Stem Cell Tissue Bank at the National Institute for Biological Standards and Control (NIBSC) in Hertfordshire in 2003. The cleanroom facility was realised within three adjoining modules and comprises three Grade B (ISO Class 5) Laboratories, each connected by a special folding stainless steel transfer hatch and Change Areas to a Grade C (ISO Class 7) Common Service Area. The facility also accommodates a liquid nitrogen storage room and an office.

The ability to pre-construct the cleanroom facility off-site also persuaded the Royal Free Hospital in London to choose for a modular cleanroom facility. The modular pharmacy unit, which extended the existing pharmacy manufacturing facility, meant that the hospital could continue to use the existing facility right up to the point where the break through was made to join the new modules to the old facility.

When thinking of modular cleanrooms, most people think of small temporary containerised cleanrooms, but constructing modular cleanrooms is not limited to size or height. Modular cleanrooms can also be large, multi-storey cleanroom facilities. Shortly after NIBSC’s facility, a new free-standing two-storey modular building was completed for the Pharmacy Department at Glan Clwyd Hospital in North Wales. The MHRA approved facility was constructed from fourteen pre-fabricated modules, making it one of the largest modular Clean Room facilities in the United Kingdom. The facility proved that even modular building can host multi-storey cleanrooms.

Site restrictions can be a reason for choosing for a modular cleanroom. In 2007, Clean Modules Ltd completed a 408 m² modular cleanroom facility for the St Georges Hospital NHS Trust in London. This facility was to be placed within the hospital’s courtyard, on top of another building and had to be lifted over the surrounding six-storey hospital buildings. The modular construction provided a lightweight but rigid structure which could be prefabricated off-site and moved into position with minimal disruption to patients, staff, emergency services and public transport. The open modules also provided a versatile space into which the state-of-the art new cleanrooms could be created without the usual size limitations imposed by portable buildings.

Clean Modules Ltd has constructed numerous modular and mobile cleanrooms over the last few years, varying from single to multi storey cleanroom buildings, and comprising from one to numerous modules. The modular cleanrooms have been used for various purposes varying from stem cell research, pharmaceutical research, biotech research to aseptic and laboratory processing. As Clean Modules Ltd constructs bespoke cleanrooms and laboratories, not two installations have been the same and the next modular cleanroom will be improved by the lessons learned from the previous modular cleanroom.

Clean Modules Ltd’s concept of modular cleanrooms has changed and with it the way of building modular cleanrooms as well. The first modular cleanrooms built for the National Institute for Biological Standards and Control (NIBSC) and Glan Clwyd Hospital in North Wales differ a lot from the current generation of modular cleanrooms build by Clean Modules Ltd.

The new generation of modular cleanrooms allow for the modular units to be bigger, stronger and more stable. While the frames of the early modular cleanrooms included some timber elements, the current generation of modular cleanrooms is constructed within a hot rolled steel frame. The early modular cleanrooms could accommodate larger facilities, but by using hot rolled steel frames, the sizes of the modular units can now be wider and longer and accommodate even bigger rooms. The stronger steel framework also means that the modules feel and behave more like traditionally constructed buildings.

The walls of the modular cleanrooms have also changed considerately. While the earlier cleanrooms were constructed out of timber and vinyl chipboard, the current wall structures are set out in cleanroom panels. These panels comprise of a PIR foam structural core or a Rockwool core, pressure bonded to pre-stressed steel skins, with a smooth “foodsafe” hard PVC laminate cleanroom surface on the inside and a weather proof surface on the outside. These panels allow for higher insulation values, better fire ratings and stronger wall structures, but also allow for easier and quicker constructions of walls.

Besides the continuing improvements to the building structure, the services within the building evolved as well. The electric services now work with a plug and play system, to enable full installation and testing of the system off site. The system is de-plugged before shipping to site and plugged back in on site. Therefore, the time for service people on site has been reduced considerably. A similar philosophy extends to the air systems and other services which can be constructed for many cleanroom installations.

Even though cleanrooms are different every time and designed to fit the customer’s requirement, the main structure and services will remain the same. Clean Modules Ltd is continuously looking for improve their modular cleanrooms, but the new generation of modular cleanrooms is at the fine front of modular cleanrooms design and quality.

Contact:
Jelle Hanse
(Export Executive)

Clean Modules Ltd.
Unit 3, Hawthorn Road,
CASTLE DONINGTON
Derbyshire
DE74 2QR
United Kingdom

Tel: +44 (0) 1332 696970
Fax: +44 (0) 1332 696963
Email: export@cleanmodules.co.uk
Web: www.cleanmodules.co.uk

Clean Modules specialise in the design, construction and project management of Clean Room installations, controlled environments, clean air and conditioning systems. In addition to specialist biotechnology Clean Rooms, the company has considerable expertise in a wide range of life science applications including pharmaceutical, medical and hospital applications. They have also built up a considerable expertise in modular and mobile facilities including units pre-built and validated off site.

This release was published on openPR.