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Cleanroom Design
Our experienced cleanroom design teams can support you with all aspects of the design and specification requirements of your cleanroom project, bringing experience and knowledge of traditional and specialist cleanroom panel systems. We can assist from project conception to facility handover and validation, with feasibility studies, Capex / budget costs, design for tender process or as part of a design and build project.
Measured building surveys
A measured building survey is an essential step in cleanroom design for several reasons. This type of survey provides precise and detailed measurements of the existing building structure, which is crucial for creating an effective and efficient cleanroom.
Data collected during the onsite survey can be used as an up-to-date site record for planned maintenance programmes, area identification, fire escape plans, quantifying and future space planning, all in one place and in an industry standard usable digital data format.
We understand that most of the existing spaces / facilities are within live critical environments, so we only use our most experienced specialist team who are very familiar with GMP and critical environment procedures.
Conceptual design
Conceptual design is an early phase of the design process where the foundational ideas and concepts of a project are developed and conveyed through layouts and other models, such as renders. It is a draft consisting of ideas and concepts about what space the room should offer, including:
- The required classification(s)
- The control of specific parameters, such as differential pressures, temperature and humidity
- Whether to apply dedicated or segregated zones
- How to best facilitate internal logistics of people and products
What's involved in conceptual design
This phase allows you to evaluate the proposed specification. It focuses on defining the broad outlines and primary structure of the project, establishing the basic functions, form, and overall vision before detailed design and development begin. We will work collaboratively with you to achieve the right combination of operational parameters that will deliver the desired results.
Flow of materials
Design cleanroom entrances and gowning areas so that personnel donning cleanroom clothing minimise contamination from outside. Incorporate transfer hatches for materials to move from one zone to the other without personnel crossing boundaries.
Room sizing
Allocate space for necessary equipment and furniture given the required ISO or GMP classification. This may involve considering any potential future need for expansion, allowing for scalability and room to adapt to future demand.
Gowning areas
Gowning areas provide a separate entry and exit into the main cleanroom area where personnel can remove contamination from the outside world. These areas may utilise air showers, step-over benches and tacky mats to control contamination.
Support areas
Storage areas and utility rooms provide a separate space to store cleanroom supplies, raw materials and any supporting equipment necessary to aid the processes undertaken in the cleanroom.
Airflow design
Calculations are required to work out the necessary Air Changes per Hour (ACH) along with other airflow paramaters in order to meet the desired cleanroom classification. This will involve deciding on the optimal number of fan filter units required.
Filtration placement
Strategically placed HEPA or ULPA filters will provide the necessary air filtration to achieve the desired ISO or GMP classification. In some cases airflow may need to be vertical or horizontal depending on the processes or restrictions of the cleanroom space.
Detailed design
In the detailed design phase, the ideas and concepts evolve into concrete plans, delivering the required specifications and exact definitions of dimensions, optimal materials and components to be used and a defined User Requirement Specification (URS).
The initial URS defines the processes, equipment, operations, capacities and the environmental criteria for the cleanroom design. In the URS, designers need to review the flow of people and products through the facility to assess the optimum layout for regulatory compliance, efficient operation and the minimisation of cross contamination opportunities.
It is vital that relevant personnel from production, quality, logistics, maintenance and engineering are involved in the early stages of the design. This avoids reworking of design layouts and minimises costly errors by overlooking or misinterpreting practical issues. Once the URS has been approved, the functional design specification (FDS) will be developed.
What's involved in detailed design
The detailed design phase of cleanroom construction is critical as it translates the conceptual design into precise, actionable plans. This phase involves comprehensive planning of architectural elements, mechanical systems, electrical systems, plumbing, and special systems. Each component is meticulously detailed to ensure the cleanroom meets the specified cleanliness standards and operational requirements.
Detailed drawings
Floor plans, elevations and sections of the facilty are defined, showing the exact layout of the walls, doors, windows and fixtures. Drawings of structural elements such as walls, ceilings and potential furniture options detail specific elevation and height paramaters.
Materials selection
Wall panels, ceiling panels and floor choices such as anti-static or chemical resistant. Fixtures and fittings also need to be defined such as LED lighting or UV protective film on the windows. Which furniture do you need?
Mechanical system design
HVAC system design needs to meet the desired temperature and humidity paramaters as well as any required pressure gradients to prevent contamination between higher and lower grade areas. This requres meticulous air filtration and ductwork design.
Electrical system design
Illumination levels need to be defined so that the lighting layout provides the required lux levels and adequate illumination for the tasks being undertaken. Circuit design and cleanroom rated fixtures need to be appointed to supply particulate free power to certain areas.
Plumbing design
Process utilities such as compressed air and gas lines may be required for certain procsses. Waste management needs to be designed to safely dispose of any waste, considering local regulations and environmental impact.
Special system design
Environmental monitoring systems are required for continious monitoring of temperature, humidity, pressure and particulate level. Some processes may require a data logging system to alert users of major changes to the operating environment.
Building information modelling (BIM)
Building Information Modeling (BIM) is an advanced technology that is increasingly used in the design, construction, and management of cleanrooms. BIM involves the creation and use of a digital 3D model to represent the physical and functional characteristics of a facility.
Using modern surveying equipment, we 3D scan the current environment of our client’s facilities and carry out clash detection to verify that the proposed cleanroom design operates in line with the planned process and its surrounding environment. 2D and 3D models allow our clients to visualise their project, including virtual reality walk-through tours to test the layout and workflow.
Due to the structural and mechanical requirements, cleanrooms are complex systems. By applying Design for Manufacture and Design for Assembly (DfMA) principles, we are able to manufacture and assemble more efficiently. This improves the installation experience for our clients, resulting in smoother project management and a shorter project lifecycle.
Our team of Autodesk certified design engineers create designs following the latest BIM standards and workflows. By working in this way, we are able to collaborate with clients and coordinate with any other contractors involved in a facility build, resulting in greater accuracy and higher quality results.
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Whether you need a consultation, pricing, or technical guidance, our specialists are ready to discuss your requirements.
Cleanroom design FAQs
Cleanroom design is a comprehensive and meticulous process that integrates architectural, mechanical, electrical, and operational considerations to create a controlled environment meeting specific cleanliness standards. The goal is to minimise contamination and ensure that critical processes can be carried out in a stable, controlled atmosphere.
HVAC systems are critical in cleanroom design for controlling temperature, humidity, and pressure, and ensuring proper airflow and filtration to maintain cleanliness standards.
The most obvious challenge is designing a facility that manages contamination control to the desired ISO or GMP class, while working within the paramaters of the provided space. Creating a process flow that is suitable for both the activities undertaken and the personnel working within the cleanroom can also be challenging.
Before committing to a cleanroom design project, it is worth establishing whether your process actually requires a controlled environment. The need for a cleanroom is typically driven by contamination sensitivity, whether that relates to particulate, microbial, temperature, humidity, or electrostatic risk. Industries such as pharmaceuticals, semiconductor manufacturing, aerospace, and medical devices commonly require cleanroom environments due to regulatory mandates or the nature of the products being handled. If you are unsure whether your application warrants a cleanroom, find out more about whether you need a cleanroom before progressing to design.
The conceptual design phase establishes the foundational layout and structure of your cleanroom. We evaluate your required ISO or GMP classifications, define specific operational parameters such as differential pressures and temperature, and map out the internal logistics of personnel and materials to ensure optimal process flow before moving into the detailed design stage.
We begin with a highly accurate measured building survey using advanced 3D scanning equipment. Our specialist design team records precise spatial data, which allows us to carry out detailed clash detection. This helps ensure your proposed cleanroom integrates effectively with your existing building structure, live processes, and mechanical infrastructure.
The URS is a critical document formulated during the detailed design phase. It clearly defines the specific processes, equipment, operational capacities, and environmental criteria required for your cleanroom. By collaborating directly with your production, quality, and engineering teams to finalise the URS, we avoid costly layout errors and ensure complete regulatory compliance.
Yes. We utilise advanced Building Information Modelling (BIM) to create detailed digital 3D models of your facility. Our design engineers work closely with you and your end users to develop the layout, workflow, and ergonomics of the space, and can provide virtual reality walk-through tours before any manufacturing or assembly begins.
Preventing cross-contamination is a central focus of our architectural planning. Depending on your requirements, personnel entry can be managed through dedicated gowning areas with features such as step-over benches, air showers, and tacky mats. For the movement of goods, we can integrate transfer hatches and interlocked airlocks, ensuring materials safely transition between segregated zones without breaching cleanliness boundaries.