23 Aug Cleanroom Walls: A Look at Materials and Systems

When designing a cleanroom, one of the most important decisions you can make is choosing the right walls and materials. Cleanroom walls are more than just barriers to the outside; they affect the cleanliness of your space, how well they hold up against cleaning agents, and how easily they can be moved. In this article, we’ll help you make the right choice by discussing the differences between the major wall systems, their materials, and more.

What’s the Difference Between Hardwall, Softwall, and Modular Cleanroom Walls?

Choosing the right wall system for your cleanroom will depend on the application, the need for flexibility, your budget, and more. To simplify your decision-making process, let’s go into a few of the main differences between each.

Hardwall Cleanroom Walls

Hardwall systems are the traditional way to build a cleanroom. They are permanent structures, and cannot be moved at a later date. They are usually much more expensive and time-consuming to build and install (when compared to modular or softwall cleanrooms). Further, once they are built, hardwall cleanrooms cannot be modified or expanded without many difficulties and high costs. As a result, we wouldn’t recommend this type of wall if you anticipate that business needs may change later.

Softwall Cleanroom Walls

Softwall cleanrooms, on the other hand, are much more flexible. They usually consist of a steel or metal frame with vinyl curtains that hang from it. These cleanrooms can even be put on wheels and moved around (they are lightweight). One downside of softwall cleanrooms, however, is that they typically do not have AC, flooring, and many other features that you might find in a hardwall space.

Modular Cleanroom Walls

Modular cleanroom walls are in the middle ground between hardwall and softwall systems. Though technically, softwall and hardwall cleanrooms can also be modular. “Modular” simply means that the walls are prefabricated panels that can be quickly assembled and disassembled. In cleanrooms, these panels are usually connected by anodized aluminum framing (extrusions). A benefit of this kind of setup is that the entire building can be moved, adjusted, or expanded at a later date. They are also very customizable, so much so that it’s possible to change the wall materials as needs change.

(Before finalizing your choice, it’s helpful to review a cleanroom design checklist to make sure all your requirements are covered.)

Materials Used in Cleanroom Walls

After you’ve selected the wall system, choosing the materials is the next stop. Here are a few materials that are commonly used in the cleanroom industry.

High-Pressure Laminate (HPL)

High-pressure laminate (HPL) is a composite material often used in cleanrooms. Without getting too much into the technical details, it is like a strong sandwich made of paper. Imagine you have a few layers of thick, brown paper (called Kraft paper) and you glue them together really tightly using a special plastic that hardens when it gets hot. On top of that, you put a piece of decorated paper. When you press all these layers together with lots of pressure and heat, they stick together and become a tough, smooth surface that’s hard to scratch or break.

Pros:

• Resistant to scratches and impact.
• Moisture-resistant.
• Chemical-resistant.
• Low cost compared to stainless steel or glass.

Cons:

• Not as strong as metals like stainless steel or aluminum.
• Can be prone to edge chipping if not properly installed.

Many industries, such as pharmaceuticals, biotechnology, and healthcare, use HPL because of its cleanability and resistance to harsh chemicals in cleaning agents.

Stainless Steel

Stainless steel needs no introduction, but it is important in cleanrooms because of its corrosion resistance.

Pros:

• Strong and corrosion-resistant.
• Easy to sterilize and clean.
• Long-lasting with very low maintenance.

Cons:

• Higher costs compared to other choices.
• Heavier and difficult to install.

Steel is often used in industries that need to keep spaces very sterile, as in pharmaceuticals and biotech, since it is strong and can withstand many cleaning materials.

Aluminum

Compared to steel, aluminum has a much lighter weight, while still being a metal. Because of this, it is often applied in modular cleanrooms. Obviously, it’s not as strong as steel, but it walks the line between sturdiness and flexibility.

Pros:

• Lightweight, which makes installation easier.
• Strong, sturdy, and corrosion-resistant.

Cons:

• Might not be suitable for the harshest environments (where stainless steel would do better).
• May require additional surface treatments for cleanroom applications.

This is a popular choice in industries like electronics (because it is non-magnetic) and aerospace (for its great strength-to-weight ratio).

PVC and FRP Panels

Further, polyvinyl chloride (PVC), commonly referred to as “vinyl,” and fiberglass reinforced plastic (FRP) panels are other options. They are frequently chosen because they are low cost and easy to clean.

Pros:

• Low cost.
• Moisture-resistant / chemical-resistant.
• Easy to install and take care of.

Cons:

• Not as strong as metals, like stainless steel and aluminum. (So not a good fit for chaotic or harsh environments.)

These materials are fairly widespread, especially in modular cleanrooms, and can be found in countless industries.

Glass Walls

Finally, glass walls are used in cleanrooms where visibility is important. Transparent, non-porous, and easy to clean, glass walls are perfect for applications where monitoring activity is required.

Pros:

• Visibility for monitoring and observation.
• Non-porous, easy to clean.
• Has a modern-looking aesthetic.

Cons:

• May be more expensive than other materials.
• May be less flexible in terms of reconfiguration.

Glass walls may be used in pharmacies, research labs, and other places where observation is necessary.

Cleanroom Walls: The Bottom Line

It can be tricky to figure out what wall system and materials you need for your cleanroom. Whether you choose permanent hardwalls, flexible softwalls, or modular walls that can adapt to future changes, each option has its pros and cons. Likewise, materials like stainless steel, aluminum, HPL, PVC, FRP, and glass have different benefits depending on the requirements of your industry.

Still confused about what you need? Contact the experts at Allied Cleanrooms today for a free quote and expert guidance.