Cleanroom Manufacturing Suite -
Advanced Solid-State Sensor Company
LOCATION: Columbus, OH
PROJECT: ISO 5, ISO 6 & ISO 7 Cleanroom Suite for Aerospace Sensor & Semiconductor Component Manufacturing​
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Overview
This project highlights the design and construction of an advanced cleanroom suite for a globally recognized manufacturer of high reliability sensors for aerospace and research applications. The result was a state-of-the-art facility that exceeded client expectations while navigating complex structural and environmental challenges.
PROJECT CHALLENGE
Originally planned for a 30-foot-tall warehouse, the project pivoted to a new facility with significantly reduced vertical clearance, just 12'10" to the floor above, 10'6" to the trusses, and a required internal ceiling height of 9'6" in classified areas. Our team delivered a fully functional, ISO-classified cleanroom within these tight constraints.
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Project Scope
- Total Footprint: 110' x 35'
- Ceiling Height: 9'6" in classified spaces
- ISO Classifications:
- (1) ISO 5 Lithography Bay
- (3) ISO 6 Process Bays
- (1) ISO 7 Gowning Room
- Clean Chase Corridor for Maintenance and Airflow
The clean chase design was critical in accommodating mechanical systems within the limited vertical space while ensuring optimal airflow and maintenance access.
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Mechanical Design
- HVAC Configuration:
- (2) Air handling units with chilled water coils
- Units placed within the clean chase to serve classified zones
- Fed by an air-cooled chiller located adjacent to the building
- Environmental Specifications:
- Temperature:
- ISO 5 zone: 68°F ±2°F
- Other zones: 68°F ±3°F
- Humidity: 50% ±5%
- Plenum Cap: The existing second-floor deck was used as a plenum cap, with a gasketed grid ceiling system suspended from building trusses.
- Additional Features:
- RO water system supporting duct-mounted humidifier
- Strategically placed electric reheat coils to prevent cold spots
- Exhaust ductwork for client’s process flow hoods, routed per building code
- Fire suppression sprinklers
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Construction & Finishes
- Wall Panels: FM-4880 Class 1 fire-rated, ASTM E84 compliant
- Doors: Custom-painted swing doors to match client branding
- Flooring: Epoxy finish installed by client
- Specialty Features:
- Viewing corridor with oversized windows for customer tours
- Lithography bay outfitted with specialty window film and lighting
- Pass-thru cabinets, large paired door access, and panel cutouts for process equipment
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Controls System
Western Environmental provided a fully integrated PLC-based control system, designed, programmed, and built in-house:
- Live Monitoring Screen in Gowning Room: Displays real-time metrics for all classified zones, including:
- Room temperature and humidity
- Room pressure
- Fan and smoke detector status
- Coil and supply air temperature
- System alarms
- Average conditions by zone
- Controls Panel: Built and pre-wired in our Ohio facility with all low-voltage wiring in conduit for reliability and code compliance
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Commissioning & Certification
Upon construction and start-up completion, our certified testing team conducted a full commissioning process, including:
- Particle count verification
- Room balancing
- Airflow measurements
- Lighting level verification
- Pressurization checks
- Humidity testing
All testing was conducted using instruments calibrated to NIST-traceable standards in accordance with our ISO 17025 accreditation. Testing complied with ISO 14644 requirements.​​
Results
Despite challenging spatial constraints, the cleanroom suite was delivered with exceptional quality, operational precision, and full ISO compliance. The space now serves as a flagship manufacturing environment for high-precision sensor production.​
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Check out our Design and Build Approach
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Begin Your Project
From clean room design to CMM enclosure expansion, Western Environmental is your source for ISO 17025 accredited controlled environment services. Get a quote online or call us at 513-422-4088 for more information on how we can help.