The entire process of modular assembly of clean rooms
I. Pre-construction Preparation
Site Survey and Layout：Clear debris from the construction site, level the foundation floor, and mark the center lines of the cleanroom walls, column positions, and ceiling elevation lines according to the construction drawings. Mark the reserved positions for air handling units, ducts, and pass-through windows. Verify the specifications of the cleanroom color steel panels, aluminum profiles, and accessories. Ensure the panels are stored properly upon arrival to prevent moisture damage and air leakage.
Main Material Inventory：Core main materials: Machine-made/handmade rock wool/magnesium oxide cleanroom color steel panels, aluminum alloy aluminum profiles, angle aluminum, edge trim, cleanroom doors, cleanroom observation windows, pass-through windows; Auxiliary materials: Neutral silicone anti-mildew sealant, expansion bolts, self-tapping screws, rubber sealing strips.
II. Enclosure Wall Assembly (Core Process)
Groove Fixing：Lay U-shaped grooves along the marked points and fix them to the ground with expansion bolts. Rubber sealing strips can be installed inside the grooves to prevent dust and water leakage from ground gaps. For damp workshops, additional waterproofing strips should be added.
Wall Panel Interlocking Assembly：The cleanroom panels feature tongue-and-groove joints on their sides. The first panel is vertically fixed by inserting it into the groove. Subsequent panels are joined together using these joints, ensuring vertical seams are aligned. Corner aluminum profiles are used for edging; right-angle and rounded corners are selected according to requirements. Throughout the process, panel flatness and verticality error ≤2‰ are guaranteed.
Pre-reserved Openings and Embedded Holes：During wall panel assembly, pre-reserved openings are made for cleanroom door openings, observation window openings, pass-through window openings, and Venturi valve/pipe penetration holes. Reinforced aluminum frames are added to the edges of these openings to prevent panel deformation and cracking.
III. Ceiling System Installation: Hanger and Keel Frame Installation: Expansion hangers are pre-embedded in the ceiling slab. T-shaped cleanroom keels are installed, and the keel frame is fixed according to the ceiling layout. The ceiling's levelness is controlled, and load-bearing points are avoided near ductwork and lighting fixture openings.
Ceiling Panel Assembly: The cleanroom ceiling panels also use tongue-and-groove splicing, with the panel seams fixed to the keel. FFU (Fan Filter Unit), HEPA filter, and cleanroom lighting fixtures are directly embedded into the pre-reserved frame in the ceiling. Large equipment locations are reinforced with keels.
IV. Cleanroom Door and Window, Pass-Through Window Assembly:
Cleanroom Door Installation：Door frames are pre-installed with rubber sealing strips, embedded in the pre-reserved door opening in the wall. After leveling and fixing, the edges are sealed with sealant. Single/double-opening cleanroom doors are equipped with door closers and airtight locks. Anti-collision cleanroom doors are fitted with anti-collision strips.
Observation and Pass-Through Windows：Double-glazed cleanroom observation windows are embedded in the pre-reserved frame in the wall, with all four sides fully sealed with anti-mildew sealant. Electronic/mechanical interlocking pass-through windows are fixed at the wall opening, with the gaps between the cabinet and the wall panel fully sealed to ensure airtightness of the cavity.
V. Ductwork, Purification Equipment, and Piping Installation
After the wall panels and ceiling are completed, electromechanical installation is carried out concurrently: Fresh air ducts and return air plenum boxes are connected to the ceiling-mounted FFUs and HEPA filters; water supply, drainage, and electrical wiring pass through the walls via pre-embedded sleeves in the wall panels, and the gaps between the wiring are sealed with sealant to prevent dust from seeping into the clean area; differential pressure gauges and temperature and humidity probes are installed with pre-drilled holes and the gaps are sealed.
VI. Cleanroom Floor Construction
1.Sealing Gaps：Neutral, mildew-resistant silicone sealant is applied to all joints between wall panels and the floor, wall panels and the ceiling, all doors and windows, and equipment and materials. This is crucial for controlling dust leakage in the cleanroom; the sealant surface should be smooth without gaps or bubbles.
2.Cleanroom Flooring Installation：Select the appropriate type based on the cleanroom's grade: PVC anti-static roofing membrane, epoxy self-leveling flooring, or polyurethane flooring. Roofing membrane joints are hot-melt welded, and corners are rounded to eliminate dust accumulation dead zones.
VII. Final Inspection and Cleanroom Acceptance
1. Cleaning and Blowing: Remove the protective film, thoroughly vacuum and sweep, wipe away adhesive residue and dust from the boards, and seal any temporary openings.
2. System Trial Run: Turn on the FFU and air conditioning purification unit for continuous air blowing, and perform self-cleaning according to the cleanroom class (Class 10,000/Class 1,000/Class 100).
3. Third-Party Testing: Test for suspended particles, airborne bacteria, temperature and humidity, pressure difference, and air exchange rate. The system is put into use after meeting the standards.
Supplementary Knowledge
1. Tongue-and-groove splicing of cleanroom panels + full seam sealing is the core of airtightness. Air leakage through gaps will directly lead to substandard cleanliness and uncontrolled pressure difference.
2. For Class 100 and higher cleanrooms, handmade magnesium oxide boards are often used for ceilings and wall panels, which are stronger and less prone to deformation.
3. The purpose of rounded corners and floor radius (R-angle) design is to eliminate dead corners, prevent dust accumulation, and facilitate daily cleaning and disinfection.