Functional Design at a Reduced Cost

Unlike their fixed-wall counterparts, softwall cleanrooms are generally smaller, portable and can fit into tight spaces. The portable design enables the cleanroom units to be easily moved to another location or disassembled and stored. Because of their relative low cost, softwall cleanrooms are ideal for small or startup businesses, or manufacturers looking for a quick, easy way to expand their cleanroom operations.

Softwall Modular Cleanrooms for any Application

The cleanrooms are available in a variety of sizes and classifications, with options to match a customer’s specific needs. From standard 4-by-4-ft units, to sizes as large as 24-by-36-ft. Larger, custom sizes can be designed and built to meet customer requirements.

Due to their modular design, rooms can be expanded or reduced in size without taking the entire cleanroom down, making it easy to add or remove sections. Softwall rooms are also available in a variety of cleanroom classifications, but most commonly in Class 100,000 to Class 10 (ISO 8 to ISO 4) designs. Numerous industrial manufacturers regularly utilize softwall modular cleanrooms, some of which include:

  • Medical Device Manufacturers
  • Microelectronic Manufacturers
  • Semiconductor Manufacturers
  • Electrical Repair Facilities

Designed for Easy Assembly

The basic building block of the softwall cleanroom’s modular design is a sectioned ceiling framework made up of tubular steel beams with T-bar cross members. This interlocking ceiling grid system enables easy assembly and cleanroom expansion. The ceiling is supported by tubular steel legs at each of the four corners and reinforced with heavy gauge, triangular steel gussets. Powered HEPA filter units, lighting systems and ceiling panels are sealed to the grid using gaskets, providing a zero-leak cleanroom.

Interior height of the ceiling framework is commonly 8, 9 or 10 feet, although various heights are available depending on the customer application. Standard filter unit height is 14 inches, with a two-inch minimum space required between the filter unit and facility ceiling. The common structure height enables the modular softwall cleanroom to easily fit within an existing building.

Softwall Cleanroom Wall & Door Construction

The walls of most standard softwall modular cleanrooms are made of 20 or 40 mil clear vinyl and are fire retardant with an anti-static additive. Cleanroom grade softwalls with low outgassing and static-dissipative vinyl are an option. Vinyl strip doorways commonly consist of eight-inch-wide, 80-mil thick strips with a two-inch overlap on each side along the length. The strips are pushed apart for entry/exit and automatically reseal as they come back together. The strip doors are pre-assembled and are easily mounted to the ceiling structure. Swinging doors in metal frames are an available option when acrylic or Lexan walls are used.

Modular Cleanroom Filter Requirements

The controlled level of contamination will vary depending on quantity and configuration of filters. When ceiling space for lighting is limited due to filter requirements, flow-thru lights can be used. These are like standard clean room lights with the exception that a motorized ceiling HEPA filter unit is mounted directly on top of the light. This fixture is designed with open areas so filtered air can flow through the light fixture down into the clean room. The filter unit and light fixture are pre-assembled together to form one complete flow-thru light unit.

Filtered air is exhausted from the cleanroom beneath the flexible vinyl walls. An adequate gap of about 6 inches between walls and floor is necessary for air to flow through the room and escape. Air volume is typically about 200 feet per minute, and at that rate the flexible walls tend to bow outward a little because of positive air pressure created by the powered filters. A small amount of wall flex is normal, but if the wall-to-floor gap is too small, the air will push the panels outward to an unacceptable distance and inhibit good laminar airflow. If the gap is too large, the cleanroom will not keep enough positive pressure to push contaminants out.

[Filter Unit Diagram]

Special Requirement Options

Softwall cleanrooms have many options available depending on customer needs. Some of the custom options that can be added to our softwall modular cleanrooms, include:

  • Anteroom Addition
  • Gowning Room Addition
  • Braked Casters to add Mobility
  • Acrylic & Lexan Panels
  • Special Room Height Modifications
  • Solid Doors
  • Yellow or Opaque Side Walls
  • Stainless Steel Frames
  • Building Suspension Brackets
  • Ionization Equipment
  • And More

Modular softwall cleanrooms are prefabricated at the factory for quick installation. Customers can easily install standard rooms onsite quickly and effectively. All electrical connections are simplified using a continuous series of plug-together pre-fabricated wiring system. Starting at the room’s electrical junction box, power cable segments are connected to each ceiling light and powered filter unit. This allows the user to connect any number of lights or filter units within their circuit.

Modular Cleanroom Maintenance

Softwall cleanroom maintenance is relatively simple but regular cleaning is required to ensure optimum performance. Powered filter units use a prefilter and these must be visually checked on a regular basis. If the filters are dirty, they must be changed. The HEPA filters are somewhat maintenance free, but it is recommended they be re-certified by a third party every year. All interior surfaces and floors must be cleaned on a regular basis.

Softwall Modular Cleanrooms for your Project Needs

A modular softwall cleanroom is a low-cost investment that provides a highly functional cleanroom solution for manufacturers. The flexible structure creates a controlled environment that can meet the needs and requirements of small- to large-sized companies. Softwall cleanrooms are designed with the customer in mind, covering a wide range of industries and diverse applications.