17 Apr The Costs Involved with Over- or Under-Engineering a Cleanroom

Many people believe that it seems safer to overbuild a cleanroom “just in case.” After all, if a space is cleaner than necessary, isn’t that obviously better than the alternative?

Not always. In fact, over-engineering can lead to increased construction costs, oversized HVAC systems, a lot of wasted energy, and higher maintenance for features that you may never have needed in the first place.

On the other hand, pinching pennies on upfront costs often results in under-performing spaces that can fail inspections, add to contamination, and require expensive retrofits later on.

In this article, we’ll cover the most important factors that influence cleanroom costs, how over- or under-engineering can affect your finances, and more.

Factors That Influence Cleanroom Costs

Planning early and correctly for cleanroom projects has a huge impact on how much it will cost, both to build and to run. Things like how clean the space needs to be, how much air has to move through it, and what materials are used all play a role in the final price. Here are some of the main factors that influence cleanroom costs.

Cleanroom Classification

Cleanroom classifications generally set the standard for how strict (or permitting) a cleanroom will be. Specifically, ISO classifications are based on how many particles are allowed in a given air volume.

For example, an ISO Class 5 cleanroom allows no more than 3,520 particles per cubic meter (≥0.5 µm), while an ISO Class 7 cleanroom allows up to 352,000 particles per cubic meter.

There is only one cleanroom class between them, and yet there is a 100-fold difference in the particles they allow. As you might expect, this results in stricter controls and therefore significantly higher costs.

Air Changes Per Hour (ACH)

Because higher classifications require cleaner spaces, they also require more air changes to keep particle levels low. Though the measurement is by no means perfect, an ISO Class 5 room might need 240-480 ACH, while an ISO 7 space might only need 60-90. The number of air changes required can directly impact your HVAC design and energy use, and therefore also the cost.

Materials, Architectural Finishes, & Surfaces

Further, cleanroom walls (architectural finishes), ceilings, and floors must be easy to clean, suitable for whatever cleaning materials you’re using, resistant to shedding, and more. In some cases, overbuilding with high-end materials can inflate costs unnecessarily. Yet, on the other hand, using substandard materials may add to contamination or even the failure of your operation.

Utility/HVAC Demands

Last but not least, there’s a risk of over- or under- engineering a cleanroom’s HVAC system. This system helps control the air movement, temperature, and humidity in a cleanroom.

If the system is too small, it may not keep the room clean or stable enough. If it’s too big, it wastes energy and costs more to run going forward. Getting the airflow and pressure just right is important to making the room work the way it should.

The Financial Impact of Over-Engineering

When a cleanroom is built to higher standards than necessary, companies often assume they are playing it safe. But over-engineering comes with a price that continues long after construction ends.

Higher Capital Costs

Building an ISO Class 5 cleanroom when an ISO Class 7 space would do can increase expenses significantly in HVAC, filtration, and materials. This includes high-end finishes and air handling units that are better used for stricter classifications.

For example, a pharmaceutical company once installed ULPA filters, which remove 99.999% of particles, even though standard HEPA filters would have fully met their requirements at a much lower cost. In some cases, semiconductor manufacturers, for instance, may install extra HVAC units as a precaution. While they may rarely be used, including them can still significantly raise construction costs.

Increased Energy Use

Furthermore, when systems are overbuilt, they run harder and longer. As a general rule, higher air change rates demand more power, and larger HVAC units pull more electricity to maintain clean conditions that might not even be required. Maintaining an ISO Class 5 cleanroom, for instance, can cost two to three times more in energy than an ISO 7 one.

Higher Maintenance

Additionally, extra filters, sensors, and ductwork can mean more equipment to check and replace. Routine maintenance can become more expensive and time-consuming.

Inefficient Use of Space

Finally, over-engineered cleanrooms can be harder to adjust and adapt. If only a portion of the room needs higher classification, companies may find they’ve wasted money designing the entire area to stricter specifications.

The Financial Impact of Under-Engineering

On the other hand, cutting corners can also impact expenses. Though upfront prices may be lower, under-engineering eventually backfires. The result is often a space that doesn’t meet regulations or else fails under actual operating conditions.

Contamination and Product Loss

A cleanroom with insufficient airflow, the wrong pressure differentials, or inappropriate architectural finishes can lead to contamination or even the failure of your project. In manufacturing, this translates to lost batches, lower revenue, and even possible product recalls and legal problems.

Retrofitting Costs

Sometimes, under-engineering a cleanroom can actually result in more costs. A poorly built cleanroom, for instance, often costs more than getting it right the first time, simply because of all the changes you’ll have to make. Retrofitting HVAC, changing wall panels, or installing proper filtration after construction can delay operations for weeks, months, or even longer.

Downtime and Delays

Finally, if a room fails certification or validation, operations may have to grind to a halt completely. For most businesses, this is the worst case scenario. Re-validation, inspection rescheduling, and staff training can significantly add to your timelines and costs.

The Bottom Line

In short, over-engineering ends up wasting your money, while under-engineering risks failure (and sometimes even more costs!). Cleanrooms that don’t meet actual process requirements as best they can tend to cost more, whether that’s upfront or later. The best approach is to design for what’s truly needed, with nothing more, nothing less. That means understanding the process, the risks, and the standards before locking in your cleanroom specifications. If you get that part right, you’ll help your business avoid the most expensive mistakes.

Interested in setting up cleanrooms the right way? Reach out to Allied Cleanrooms to get a quote on new controlled environments today!