
01 Feb Modular Cleanroom Walls: Pros & Cons of Finishes & Systems
With so many options for modular cleanroom walls, how do you know what to choose? Making the wrong choice in wall systems, materials, and other configurations can seriously harm your project. However, with the right information, you can choose modular walls, finishes, and systems that help you stay both compliant and effective. In this article, we’ll cover the pros and cons of various modular cleanroom wall types, systems, and architectural finishes.
Understanding Materials & Finishes: uPVC, Melamine, FRP, and Epoxy-Coated Gypsum Board
When it comes to modular wall materials for cleanrooms, uPVC (polyvinyl chloride) is known for being easy to clean and highly resistant to chemicals, which makes it a top choice for cleanrooms. FRP (fiberglass-reinforced plastic) is also easy to clean, but is better for spaces with high moisture and frequent disinfectant use, as in pharmaceutical manufacturing (NIH study on disinfection efficacy).
Melamine and epoxy-coated gypsum board are other honorable mentions, especially if you’re on a budget, but they may not be the best for the strictest spaces.
Let’s take a deeper look at each, and evaluate their pros and cons.
uPVC (Polyvinyl Chloride)
uPVC is a popular choice for cleanrooms that require the highest levels of cleanliness. Its smooth and non-porous surface makes it easy to clean and take care of, and it is particularly valued in pharmaceutical and life science applications. It does, however, tend to be a bit more expensive than other finishes and materials.
Pros
- Highly resistant to chemicals.
- Easy to clean.
- Smooth & non-porous.
- Great for strict environments.
Cons
- May be three times more expensive than other choices.
- Can be susceptible to scratches if not handled properly.
- Not many cleanrooms are built using uPVC, so there aren’t many studies on its cleaning and disinfection.
- Limited information on how well it holds up to long-term exposure to chemicals like peracetic acid and other caustic substances.
FRP (Fiberglass-Reinforced Plastic)
Furthermore, there’s FRP, which has been a trusted material in cleanrooms since at least the 1930s. While it may not appear as innovative or new, it does have a long-standing performance in wet environments and compliance with fire ratings. Recent advancements in post-to-panel sealing have made this possible, and have addressed previous issues such as cracks, improper sealing, dust permeation, and air leaks. As long as proper installation and joint sealing are implemented, FRP can be very effective.
Pros
- Long history of success in cleanroom applications.
- Reliable performance in wet and humid spaces.
- Can meet required fire safety standards.
- Lower cost, especially compared to premium materials like uPVC.
- Recent innovations in sealing techniques greatly reduce contamination risks.
Cons
- Perceived as less innovative compared to newer materials.
- Requires joint sealing for best performance.
- Can experience surface wear over time if not maintained.
Melamine
Melamine panels are also sometimes used for cleanrooms, and they are generally considered a low-cost choice, especially for those that do not need to meet the strictest standards. While choosing melamine may help you save on costs, it can also require more frequent replacement.
Pros
- Lower cost choice.
- Easy to clean, with smooth and non-porous surfaces.
- Lightweight.
- Resistant to minor scratches.
Cons
- Not very resistant to harsh chemicals and disinfectants.
- May not perform well in high-humidity or wet environments.
- May have a shorter lifespan.
Epoxy-Coated Gypsum Board
Finally, there’s epoxy-coated gypsum board, which is another affordable material used in cleanrooms. The epoxy coating gives it some degree of resistance to chemicals and moisture, but if the coating is compromised, it may cause contamination problems.
Pros
- Low cost compared to premium materials like uPVC or FRP.
- Smooth, cleanable surfaces.
- Has moderate resistance to chemicals and moisture.
Cons
- Easily damaged if the coating is compromised.
- May not perform well in environments with high humidity or frequent cleanings.
- Can be prone to chipping or cracking, exposing the underlying gypsum. (This can cause further contamination to your cleanroom.)
- Shorter lifespan compared to tougher materials like FRP or uPVC.
How to Choose the Right Material
Now that we’ve given a basic rundown of the various materials and architectural finishes that can be used in cleanrooms, let’s try to create a basic heuristic for how you can decide:
- If you will have a high degree of chemical exposure in your space, then consider uPVC.
- If your space will have high humidity/moisture or frequent cleaning, then consider FRP.
- If you only need a standard cleanroom with basic cleaning needs, then consider melamine.
A Look at Cleanroom Wall Systems
Choosing a modular cleanroom wall system, luckily, is a bit more straightforward than choosing architectural finishes and materials. The biggest decision you’ll need to make is whether to go with a post-and-panel, seamless, or monobloc wall system. And each, of course, has its own benefits and limitations, mainly concerning cleanliness and flexibility.
Post-and-Panel Systems
Post-and-panel systems are exactly what they sound like. A system of panels and vertical posts (like H-posts), wherein the panels fit in together and are sealed. The vertical posts/beams are typically visible, and protrude slightly.
Pros
- Very flexible; can add and remove panels easily, which makes upgrading or changing your cleanroom at a later date simple.
- They create a self-supported structure, without needing to integrate into an existing building (as with liner panels).
- Can easily incorporate electrical outlets, ethernet ports, or other wiring through the posts; environmental monitoring sensors can also be set up through the posts and railing.
- Doesn’t require a complex ceiling structure, which can help reduce construction costs.
Cons
- May be harder to clean because of the seams/lack of smoothness on the wall; particles can build up there, so it may not be best for the strictest applications.
Seamless Systems
Seamless systems, on the other hand, are much smoother. The panels are studless, with no visible vertical posts.
Pros
- Easier to clean and maintain.
- Great for the highest standards of cleanliness.
Cons
- Difficult to adjust, upgrade, or reconfigure.
Monobloc Systems
Monobloc systems are still technically under the category of seamless cleanrooms, as they also create flush and even surfaces. However, unlike traditional seamless systems that use chemically welded plastic panels or sheets, monobloc walls are made from steel panels and sealed with caulk.
Pros
- Many monobloc systems include walkable ceiling panels, which makes maintenance much easier.
- Tight joint lines that make the walls smooth and easy to clean.
- Steel construction makes monobloc walls strong and resistant to impact.
- Often have better fire resistance and insulation compared to plastic-based systems.
- Monobloc panels are fully demountable, which gives the option for expansion or relocation at a later date.
Cons
- May be more expensive than other wall systems.
- Caulked seams may need occasional upkeep to keep the airtight seal intact.
Types of Modular Cleanroom Wall Panels
When you add everything together, cleanroom wall panels can have many different configurations, each of which may cater to different requirements and preferences. Let’s take a look at a few of the most common types used in cleanrooms today.
Insulated Metal Panels (IMPs)
Insulated metal panels consist of a foam core (such as polyurethane) sandwiched between metal facings. They can be used for walls as well as ceilings.
Pros
- Excellent thermal insulation.
- Strong and sturdy.
- Available in various thicknesses.
Cons
- May have higher upfront costs.
- May be heavier than other choices
Liner Panels
Liner panels are another choice for modular cleanrooms, especially if you want to update existing walls. You can think of them as creating a new surface in an existing structure; as a result, they are not very thick, usually only ½ an inch.
Pros
- An easy and affordable way to upgrade your facility.
- With them, there’s no need to replace existing wall systems.
Cons
- May not be as strong as standalone panels.
- They cannot be used as a primary wall without existing support.
Composite Panels
Composite panels are made from a variety of materials. Technically, IMPs would be considered a type of composite panel; however, there are other choices that are worth mentioning, including materials like fiberglass-reinforced plastic (FRP), uPVC, and other aluminum/plastic choices.
Pros
- These panels are fairly lightweight.
- Typically lower cost.
Cons
- More prone to damage from impact.
The Bottom Line
Modular cleanroom walls can come in many different ways, and choosing the right setup is important to reach compliance and run a successful operation. Each choice or configuration has its own benefits and trade-offs, and understanding these is an absolute necessity to find the best fit for your cleanroom and avoid expensive mistakes.
Still need help selecting the right cleanroom walls for your project? Contact the experts at Allied Cleanrooms today for guidance and a quote on new controlled environments: