In 2023, more than 89% of construction firms faced difficulties in hiring skilled labour. As the industry strives to attract new talent, firms are seeking innovative solutions to keep projects on track, particularly in complex environments.
For cleanroom construction, critical for sectors like semiconductors, life sciences, medical devices, and battery manufacturing, the trend of off-site manufacturing (OSM) offers a promising solution to the nationwide labour shortages.
The evolution of cleanroom construction
Traditionally, cleanroom construction has been a labour-intensive endeavour, especially the installation of ceiling grids.
Delays not only extend project timelines but also increase costs
This onsite construction involves multiple steps, including measurements, cutting, assembly, and installation—all conducted within the confines of the cleanroom environment.
This method can pose several challenges:
Time constraints: On-site construction can be subject to delays due to various factors, including weather conditions, material availability, and manpower issues. These delays not only extend project timelines but also increase costs.
Precision and quality: Achieving precise measurements and ensuring consistent quality amidst on-site construction can be challenging. Even minor discrepancies in dimensions or material quality can compromise the integrity of the cleanroom environment and require future adjustments to get the cleanroom functioning at the appropriate class level.
Waste and environmental impact: On-site construction can generate significant waste, including excess materials, packaging, and debris.
The rise of offsite manufacturing
To address these challenges, offsite manufacturing—or modular construction—has emerged as a popular approach to cleanroom ceiling grid projects.
We can avoid having to work around other trade partners onsite and allow them to have the space
This approach involves prefabricating components in a controlled factory environment, followed by assembly and installation at the construction site.
Key elements of offsite manufacturing include:
Precision Engineering: Offsite manufacturing facilities utilise advanced technologies such as Building Information Modelling (BIM) Revit design, and automated machinery to ensure precise measurements and high-quality fabrication.
This precision minimises errors and ensures consistency across all components.
Streamlined production: By centralising production in a dedicated facility, offsite manufacturing eliminates the inefficiencies associated with on-site construction. Workflow optimisation, standardised processes, and just-in-time delivery mechanisms enhance productivity and minimise project timelines.
Quality assurance: Offsite manufacturing allows for strict quality control protocols, including regular inspections and testing procedures by experts that are familiar with cleanroom design and manufacturing. This commitment to quality ensures that prefabricated components meet or exceed industry standards, reducing the risk of defects or structural issues that may occur with onsite manufacturing.
Sustainability: Offsite manufacturing promotes sustainability by minimising waste generation and reducing carbon emissions associated with transportation. By optimising material usage and recycling processes, modular construction contributes to environmental conservation efforts.
The benefits of OM for cleanroom owners
Advanced cleanroom ceiling systems represent complex architectural design, and their proper construction requires strategic partners that can deliver the right solution.
Modular ceiling grids, like the Clean-Trak and Flex-Trak Hybrid designs, support an off-site manufacturing model.
Modular and hybrid options show a 48% reduction in additional structural steel cost, and assembly of it
They are fully assembled at the factory and delivered complete, ready to be installed, reducing the need for more fabrication and intensive onsite labour.
These modules are designed to be compatible with the cleanroom's layout, requirements, and provide:
Faster speed of installation: Modular ceiling grids are known for their rapid installation process, as most components are welded or bolted at the factory and ready for assembly on-site. This can significantly reduce construction timelines, minimising downtime during cleanroom setup or renovations.
Precision and consistency: Since modular components are factory-made, they tend to have higher precision and consistency in terms of measurements and quality, resulting in a more predictable cleanroom environment.
Customised components: Although modular systems are standardised, they often offer customisation options to accommodate specific cleanroom requirements, such as wiring, lighting, fire protection, and enhanced walkability.
A case study: Leveraging OSM in semiconductor cleanroom renovation
When one of the top producing semiconductor players was evaluating a full facility renovation in New Mexico, the player faced significant challenges in getting a decommissioned building up to cleanroom standards, increase cleanroom size, functionality and adding Automated Material Handling Systems (AMHS), all while attempting to avoid a full demolition.
To accomplish this, the industry leader turned to Nortek Air Solutions to help repurpose and retrofit the space as a Class 1000/ISO 6 cleanroom, with a goal of maintaining an 18-month timeframe and keeping the project within budget parameters.
To successfully hit the goal, the facility needed a complete overhaul of the cleanroom spaces, expansion in size, and to incorporate Automated Material Handling Systems (AMHS), which would add additional load requirements to the existing structure.
In a retrofit of this size, leveraging design resources, like Building Information Modelling (BIM) Revit design services, ensures that there are seamless integrations into the existing structure and that all future load requirements and functionality are addressed.
Offsite manufacturing allows for strict quality control protocols
Solving these obstacles meant incorporating cleanroom ceiling design concepts that used multiple types of offsite assembled grids and plenums into existing spaces.
Because the facility was undergoing significant retrofitting, offsite manufacturing allowed the ceiling grids and plenums to be constructed to the schedule, without taking up valuable square footage in the facility.
Through offsite manufacturing, the ceiling grids and plenum modules are preassembled with integrated lighting and fire protection hardware, further reducing any quality concerns during installation.
"We explore using modular construction whenever possible," said a supervisor at JE Dunn. "We can avoid having to work around other trade partners onsite and allow them to have the space. It makes the site more accessible for others that can’t work offsite and allows us to keep on schedule."
The ISO Class 6 cleanroom required an amount of recirculated air to reliably maintain the level of specified air cleanliness
Once the ceiling grids and plenum modules arrived at the facility, they were lifted into place easier and faster, compared to assembling the ceiling system on location.
"Not only is it an easier installation, but it’s also safer for construction crews," explained the JE Dunn supervisor. "There is less onsite material handling involved which means decreased potential for injury."
The ISO Class 6 cleanroom required an amount of recirculated air to reliably maintain the level of specified air cleanliness, and the amount of recirculation in the original facility plan could not meet that level.
To address the recirculation requirement, custom fan-driven Forced Return Air Chimneys (FRAC) were installed. Typical FRACs are between four feet and six feet in length.
In total, this retrofitted cleanroom reached 130,000 sqft of cleanroom ceiling system
But with this facility, over 700 16-foot long FRACs were needed, with all structural frameworks assembled offsite.
The amount of labour and space needed to assemble onsite would have pushed the project off its 18-month timeline and added significant installation complexity at the facility. Through OSM, the project saved time, reduced the workforce needed, and saved on installation costs.
"The largest factor with offsite manufacturing is planning for the path to bring the ceiling grid or air handler into the space,” said the JE Dunn supervisor. “This makes site walks and working with experienced partners in the cleanroom industry important, especially as we see newer skilled labour coming that may not have the experience."
In total, this retrofitted cleanroom reached 130,000 sqft of cleanroom ceiling system. By leveraging offsite manufacturing to deliver these critical performance components complexity at the facility was reduced and saved a considerable amount of time and expense when compared to the alternative of a complete greenfield project.
On-site construction can generate significant waste, including excess materials, packaging, and debris
Measuring the value of offsite manufacturing
As offsite manufacturing capabilities are evaluated, it’s worth noting that in a third-party independent study commissioned by Nortek Air Solutions CleanSpace, data confirmed:
48% reduction in additional structural steel cost, and assembly of it, with modular and hybrid options compared to onsite assembled stick-built ceiling design.
This improved field labour cost-efficiency. Modular ceilings are easier and faster for onsite teams to install, leading to an estimated 25% reduction in total labour hours at the construction site compared to stick-built ceiling design.
What cleanroom owners should expect from partners that deliver offsite manufacturing
When opting for offsite manufacturing for cleanroom ceiling grid projects, owners should expect a seamless and collaborative process, including:
Consultation and design: Collaborative consultation between cleanroom owners, architects, engineers, and manufacturing partners is essential to define project requirements and design specifications. Ask your potential manufacture partners if they can provide Building Information Modelling (BIM) Revit design to ensure a seamless integration of all components of the retrofit, ensuring the project addresses all partner and product solutions.
Production and fabrication: Once design specifications are finalised, manufacturing partners begin offsite manufacturing and fabrication of prefabricated components. Utilising advanced technologies and industry best practices, your partners will ensure precision engineering and adherence to quality standards throughout the manufacturing process.
Logistics and delivery: Upon completion, prefabricated components are carefully packaged and transported to the construction site. Your manufacturing partners will work closely with onsite crews to ensure timely delivery and seamless integration into the cleanroom environment.
Installation and commissioning: With prefabricated components in hand, construction crews proceed with installation and commissioning activities. Your general contractor or installing contractor will oversee the assembly process, ensuring proper alignment, integration with existing infrastructure, and compliance with safety protocols and regulatory requirements.
Post-installation and support: Following installation, your manufacturing partner is a resource for post-installation support, including maintenance services, performance monitoring, and troubleshooting assistance. This ongoing partnership ensures the long-term reliability and performance of the cleanroom ceiling grid system.
With any additional 3,620 skilled labour jobs needed for every $1 billion in new construction, the labour shortage will continue to create challenges in project timelines and a lack of expertise. As cleanrooms navigate solutions and partners for delivering the right cleanroom ceiling solutions, OSM should be a major factor in your conversations.
