Cleanroom Installation

We treat the cleanroom as a single whole. The HVAC system, HEPA boxes, wall and ceiling panels, doors, pass boxes and air showers are designed in one project, largely manufactured by KRCLAB and installed by our own team.

HVAC, HEPA Boxes and Ceilings

We manufacture galvanised and stainless steel ductwork in our own facilities on fully automatic duct machines and install it to the design under the supervision of our engineers. HEPA boxes in any size (including top-change versions), the diffusers made for them, and exhaust and supply boxes are also our own products; the ceiling panel structure is made in the factory to suit them.

• Flex ceiling panels: HEPA/ULPA filter units, lighting, fire detectors and sprinkler heads are built into the ceiling. In walk-on ceilings, filters and lighting are maintained from the ceiling void without entering the clean area.
• Fan filter unit (FFU): stepless speed control, a HEPA filter with an efficiency of 99.995% or more at 0.3 µm, and a gasketed pre-filter.

Wall and Ceiling Panels

Panels are designed in 3D and produced with a dedicated coding system; sockets, services and medical gas lines are built into the panels in the factory and windows are fitted flush. As nothing is cut on site, installation is quick and clean.

• Epoxy-polyester painted steel panel: 0.8 mm steel sheet, a 100 kg/m³ rock wool or EPS core and aluminium reinforcing profiles; width 100–1228 mm, height 100–3000 mm, thickness 50–100 mm; any RAL colour. Class A2 fire performance, self-supporting, with an airtight locking mechanism. PVDF, PUR-PA and plastisol painted panels are also available.
• Silver-ion coating: silver ions added to the paint reduce bacteria levels by up to 99% within two hours compared with an unprotected surface.
• HPL hygienic partitions: 3, 4 or 6 mm compact HPL; impact-resistant, with every panel removable on its own. Joints are sealed with a special silicone that meets GMP and FDA requirements, and the panels are suitable for hydrogen peroxide bio-decontamination.
• Hygienic glass panels: 6+38+6, 50 mm in total; laminated and toughened, in the colour required; width 200–1128 mm, height 100–3000 mm. Manual or motorised blinds and PDLC smart glass can be added. Windows sit flush with the wall, leaving no ledges to collect dust.

Doors, Pass Boxes and Air Showers

• Doors: single and double hinged doors (manual or motorised), automatic sliding hermetic doors and high-speed PVC roll-up doors, in compact laminate, aluminium composite, stainless steel, glass or PMMA. All are gasketed and corrosion-resistant.
• Airlocks: Prolock electromagnetic interlocks stop two doors opening at once, keeping the pressure difference between rooms.
• Pass boxes: dynamic or static; stainless steel, PP or painted steel, made to size; UV lamp and counter, interlocked doors.
• Air showers and air tunnels: two- or three-door air showers and air tunnels with side or overhead nozzles; microprocessor-controlled cycles, touchscreen controls, LED lighting, HEPA and pre-filters.

Design Basis and Validation

• Temperature of 20–24 °C and relative humidity of 50–60% (unless otherwise specified)
• Laminar air velocity of 0.45 m/s ±20% beneath the HEPA filters
• Positive pressure, by supplying 10–15% more air to the room
• Sealed doors, walls and ceilings, with leak-tight HEPA filter mounting

Commissioning, testing and balancing follow the P&ID diagrams, and our team carries out the validation tests. Temperature, relative humidity, air changes per hour, pressure differences, laminar air velocity, viable and non-viable particle counts and noise levels are measured and verified. A facility management system monitors temperature, humidity and pressure, raises alarms on faults and allows remote access.