Modular Cleanroom Renovation Implementation Plan for Old Factory Buildings: Clean and Contaminated Area Separation

I. Preliminary Delineation of Existing Factory Building Foundation (Adapting to Fixed Layout)

1. Survey and map the existing factory building's load-bearing columns, main beams, floor expansion joints, existing main gates, ventilation ducts, restrooms, and equipment pre-reserved openings. Use the beams and columns as the positioning benchmark for modular partitions. Color steel plate partitions will be spliced ​​and fixed along the column edges and beam bottoms, without drilling deep holes in the load-bearing structure.

2. Delineation of the natural contamination side: The outer gates, freight elevators, storage rooms, restrooms, waste storage areas, and equipment maintenance areas of the factory building will be uniformly designated as the contamination side. The inner area of ​​the factory building, with better lighting and ventilation and away from dust and oil contaminants, will be planned as a clean production area, with modular buffer transition modules in between to prevent direct communication between clean and contaminant areas.

II. Modular Partition Design of Color Steel Panels (Hard Separation of Clean and Contaminated Zones)

The overall design utilizes prefabricated color steel sandwich panels (rock wool/magnesium oxide core fireproof clean panels) paired with aluminum profile clean finishing accessories. Modular units are assembled on-site, allowing for the addition or removal of partitions as needed, and is compatible with fixed walls and beams in existing factory buildings that cannot be altered.

(I) Three-Layer Modular Layout (Gradual Transition from Contaminated to Clean, No Cross-Sections)

1. Contaminated Zone Module (Simple Color Steel Enclosure Module) Independent color steel partitions are constructed along the existing gate, waste area, and outer packaging storage area of ​​the factory perimeter, all designated as the contaminated zone. The module is equipped with a standard airtight door, used only for unpacking raw materials, cleaning outer packaging, temporary waste storage, and personnel removing outer clothing. A 50mm dustproof skirting board is fitted at the bottom of the color steel partition wall to prevent dust from spilling onto the buffer zone. A separate exhaust module is reserved for the contaminated zone to prevent contaminated air from flowing back into the clean side.

2. Modular Buffer Transition Corridor (Clean/Contaminated Core Isolation Barrier) A single prefabricated corrugated steel plate buffer corridor serves as the sole connecting passage between the contaminated and clean areas, forming a physical partition wall that completely separates the two zones, with no other interconnecting doorways. The buffer section is divided into three standard modular units: a changing room module, an air shower module, and a pass-through window module, all assembled on-site from corrugated steel plates.

Personnel Flow: Contaminated Area → Corrugated Steel First Changing Room (removal of work clothes) → Second Changing Room (changing into cleanroom clothing) → Modular Corrugated Steel Enclosure Corridor for Air Shower → Clean Area;

Material Flow: Contaminated Area Raw Material Room → Modular Corrugated Steel Pass-through Window (double-layer interlocking) → Clean Area, without crossing personnel flow throughout;

The buffer partition wall uses a single, seamless, large-size cleanroom corrugated steel plate. Gaps in beams and columns are sealed with cleanroom sealant to prevent contamination and air convection between areas.

3. Modular Partitions in Clean Production Areas (Independent Enclosed Clean Units): The entire inner area of ​​the buffer zone is further subdivided into functional clean rooms using color steel panels, such as batching rooms, filling rooms, inspection rooms, and finished product temporary storage clean rooms. All clean room walls and ceilings are uniformly assembled using modular color steel panels, completely isolated from the contaminated area, with no shared ventilation or direct access doors/windows. Each clean area is equipped with its own FFU ceiling module, airtight clean doors, and clean observation windows, creating a positive pressure environment that relies on air pressure to prevent air infiltration from the contaminated area.

III. Key Points for Construction and Disassembly of Color Steel Panel Partitions in Fixed Layouts of Old Factory Buildings

1. Positioning Modular Partitions Based on Existing Beams and Columns: Existing factory columns serve as support points for the color steel panel partitions. Aluminum profile columns are edged and fitted to the concrete column surfaces. Color steel panels are assembled in sections to the bottom of the beams. The top is sealed with clean edge strips to seal the gap between the beams and wall panels, without the need to remove existing building components. Where existing walls and windows are encountered, color steel panels are used to create enclosed enclosures along the window edges, retaining only the clean observation windows to replace the original ordinary glass windows.

2. Complete Physical Separation of Clean and Contaminated Zones, Eliminating Loopholes: A continuous, uninterrupted solid corrugated steel partition wall separates the contaminated and clean areas, with no gaps or shared doorways. Existing doorways in the old factory building are completely sealed with single corrugated steel panels, leaving only one compliant connection point for a buffer passage. When applying epoxy/PVC cleanroom flooring, rounded skirting boards are installed at the bottom of the partition wall to eliminate unsanitary corners and prevent dust from seeping along the floor.

3. Modular Partitions for Flexible Decomposition, Adapting to Irregular Factory Spaces: The corrugated steel panels are standardized unit materials. Custom-cut modules are used to create independent rooms of varying sizes, addressing the irregular corners, equipment bases, and uneven beam structures in the old factory building. If factory equipment is adjusted later, the modular corrugated steel panels can be disassembled and reassembled to redefine the clean and contaminated areas, perfectly adapting to the fixed framework of the old factory building compared to traditional civil engineering partition walls.

IV. Supporting Modular Components for Clean and Sewage Separation (for Corrugated Steel Plate System)

1. Door Specifications: The sewage area uses standard corrugated steel swing doors; the buffer and clean areas use interlocked clean airtight doors. Doors on the clean and sewage sides are not interchangeable.

2. Material Separation: Modular double-layer interlocking pass-through windows are pre-embedded in the corrugated steel plate walls, preventing direct contact between materials across clean and sewage areas.

3. Air Separation: Modular corrugated steel plates in the clean area ceiling are paired with FFU (Fan Filter Unit) air supply, while the sewage area has independent mechanical exhaust, creating positive pressure in the clean area and negative pressure in the sewage area. Airflow is unidirectional from clean to sewage, eliminating cross-contamination.

4. Pipeline Separation: Water, electricity, and ventilation pipelines are concealed in modular cable trays along the top of the corrugated steel plate partition walls. Pipelines in the clean and sewage areas are independently laid out and do not share pipelines.

V. Core Advantages of the Renovation (Suitable for Existing Factory Buildings + Modular Cleanroom Requirements)

1. No alteration to the original factory building's load-bearing walls, floors, or roof; only prefabricated color steel panels are used to assemble and disassemble rooms, resulting in a short construction period and no damage to the civil engineering structure.

2. The modular structure allows for flexible disassembly and recombination of partitions, adapting to the fixed beam and column layout of the factory building. Future capacity adjustments allow for secondary zoning.

3. Complete physical separation between clean and contaminated areas, with unidirectional flow of personnel and materials, meeting cleanroom standards. The clean surfaces of the color steel panels are easy to clean and do not accumulate dust, aligning with cleanroom production standards.