ALUMA1

Optimizing Cleanroom Facility Design and Construction with Stick Built Modular

How can we reduce project risk while improving schedule, flexibility for change, and cost of ownership for Cleanroom construction.

INTRODUCTION

Modular construction has been known to improve quality, speed and be cleaner build, when building or renovating facilities.

In this paper, we will discuss the drivers of risk in Cleanroom construction.

COMPLEXITY AND RISK IN CLEANROOM PROJECTS

Large projects take years in design and delivery. In research and pilot scale projects delivery speed is important! Time or first to market, is everything, lives are at stake. Budgets are low, and you cannot compromise on SPEED, QUALITY or PRICE.

This is the DISCOVERY phase, start with a simple narrative. List all the requirements describing a successful outcome. Assemble the team, be sure everyone has a voice. Have an open mindset to discussing options available and consider all the crazy ideas. Collectively this will lead to a better outcome, building to the strength of the team.

In the DIAGNOSE phase, we have defined the process and the utility requirements. Next is the people, raw materials, finished product and waste flows. Then we define cross contamination risk, air change rates and pressure cascades, air locks and change rooms.

“Expect Some Change”, new data may change the scope of the project.

The next phase is DESIGN, where all the decisions for delivery must come together.

Schedules are always tight, and decisions are made with the known information, and previous project knowledge or allowances for the unknown to move forward. Reduce RISK by designing with systems that can adapt.

A key driver of RISK is not identifying at the DIAGNOSE phase decisions that will require changes during the DESIGN phase. The RISK is greater and more costly at the DELIVER phase.

Material shortages are a concern, as the smallest component can cause a delay. Involving the DELIVER team in the DISCOVERY / DIAGNOSE phases will allow them to help reduce this RISK.

TRENDS IN PROJECT EXECUTION

How to reduce the risk is by designing around systems that have flexibility for change. Will the construction be “on-site”, “off-site modular and delivery”, or a hybrid model.

ON-SITE “STICK BUILT” construction, using steel stud, gypsum board and epoxy paint has a long history and is well known to local designers and construction trades. This method is not clean build or modification. Gypsum board absorbs moisture and can be susceptible to mold (A water leak in gypsum board installation is a disaster). It is easily damaged and has a very high depreciation rate.

MODULAR CONSTRUCTION, where wall and ceiling components are manufactured off-site and then assembled on site has been the fastest growing method for the past 20+ years. They require a high level of design certainty before releasing the panels for manufacturing. A very clean build they assemble on site quickly. Most use a 2” honeycomb uPVC coated panel that allows for cold welding for an almost seamless joint. The downside is adaptability and flexibility to change. Once the seams are welded, they are difficult to remove. Adding new services is also a challenge after panel manufacturing. While not easily damaged they are difficult to replace if damaged. The use of the panels in a ceiling allows access above for service and maintenance. Consideration to the installation of HEPAs and Light Fixtures near a joint requires coordination. A good choice if you have a mature defined process that will not require modification in the future. Modules have a high rate of depreciation, typically the same as equipment.

OFF-SITE PREFABRICATED MODULES are filling a niche. The factory environment has higher rates of productivity and quality control. Limitations are in the size of modules for shipping, and the ability to make changes in the future as you are working around structural elements. Manufacturing in parallel with the construction of a new building can reduce overall project timelines. Typically, there is a premium to be paid for modules. Modules have a high rate of depreciation, typically the same as equipment.

All the above methods should be considered “SINGLE USE”. Stick built gypsum and modular uPVC panels cannot be easily moved or modified, yes there are components that can be reused, but not all. Prefabricated modules can be relocated if the process is similar.

There is an alternative.

ON-SITE “MODULAR STICK BUILT” construction using the ALUMA1 Cleanroom Wall & Ceiling System, is an alternative to traditional gypsum, and off-site modular panel methods. This system is easily understood by designers and local construction trades. The walls use a 3” wide stud and track system and ¼” aluminum panels allow installation of services within the cavity. The panels are held in place with maintenance free co-extruded PVC Coves and Battens are easily removable for repair or adding new services as requirements evolve. Flush windows can be installed in any location. The system is clean build, does not absorb moisture, the panels are hard to damage, and easily replaced if required. The ceiling is designed with components that allow it to be designed to each room’s requirements, and access above for service and maintenance.

The adaptability of the ALUMA1 system gives the project team the confidence of approving a layout earlier knowing that there is flexibility to adapt the design if a change is required. Add additional services, no problem. Reconfigure a ceiling to add more HEPA Filters to increase air changes, no problem. Add a window to see the process in another suite, no problem. Leave panels out to move in equipment, easy.

Cleanrooms built with the ALUMA1 system can be expanded, moved or modified, with a high percentage of components that can be reused. It has a high rate of depreciation, typically the same as equipment. If a client is at revenue leasing can be provided as it considered a piece of equipment that can be sold and easily relocated.

When ALUMA1 is used in prefabricated modules it offers the same flexibility for future change just as the on-site build and can easily adapt to Hybrid construction.

CONCLUSION

CAPEX cost compared to budget and speed of project delivery is the concern of the DESIGN team. Not normally discussed are total cost of ownership. Lost opportunity if a business plan changes. Maintenance and adaptability to change are someone else’s concern. Depreciation and future use value are not on the radar.

Selecting a wall and ceiling system that will allow you to be flexible and start construction faster has real advantages.

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