Cleanroom Manufacturing Suite - Advanced Solid-State Sensor Company
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.
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.
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
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
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
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.
Check out our Design and Build Approach
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.