Problem: In the past, modular cleanrooms were primarily
utilized for specialized functions
within a facility. Common applications included labs, quality control areas, and sensitive materials
storage. While these applications
still exist today, there is also a
growing need for more expansive
cleanroom environments including the segmentation of entire
manufacturing, packaging and processing areas within a facility.
Until recently, these larger applications have been reserved for more
traditional cleanroom construction methods due to size restrictions
when building with modular systems.
Solution: Today there are modular wall systems available that
can meet the demand for larger cleanroom environments while also
retaining the benefits of modular construction. Spanning heights of
up to two to three stories tall, these extra-tall wall systems provide
cleanroom contractors with a cost-effective solution to not only
build larger and taller environments, but also to provide a versatile
solution for changing business needs.
PortaFab Corporation is a modular cleanroom manufacturer who
provides extra-tall wall systems that are suited for larger cleanroom
applications. Two of their product lines in particular offer unique
advantages to cleanroom contractors who wish to meet the requirements for larger environments.
The SteelSpan product line does not require a framing system,
and is suited for quickly and economically dividing plant space from
floor to roof. With virtually unlimited heights and R-values reaching
43, SteelSpan provides contractors with a high-end solution for sectioning off entire facilities to control dust, thermal breaks, vapor barrier, temperature, humidity, noise, and other environmental needs.
An alternative solution is the PortaMax wall system. Also used
to divide plant space, this wall system is also suited for creating
free-standing buildings and cleanroom envelopes taller and
stronger than ever before possible with modular systems. The
increased wall heights with this system allow contractors to
achieve specific clearance for machinery or ceiling plenums to
conceal and house equipment. PortaFab offers a variety of wall
panels that can be utilized with the PortaMax wall system, each
featuring a variety of core materials and panel finishes for meeting specific requirements for acoustic and thermal insulation,
chemical resistance, and static control.
Advantages of building
Both PortaMax and SteelSpan
product lines offer all the advan-
tages of building with modular
systems. Most notably is the
cost-savings advantages. Modular
systems offer reduced design and
labor costs due to their pre-engi-
neered and pre-fabricated nature.
There are tax write-offs associated
with modular construction, furthering their cost-savings advantage.
Modular systems are inherently green due to their low mess
installation and re-usable nature. As highly sustainable products, cer-
tain benefits like LEED points are awarded to companies that utilize
modular systems for interior construction.
Modular systems offer a high degree of flexibility and adaptability. As pre-engineered components, they allow for easy
integration of new features like doors, windows, or equipment
pass-throughs. The ability to disassemble, modify, and relocate
modular buildings or their individual components allows a
modular structure to adapt to changing business needs, offering significant future advantages.
As the market for controlled environments expands beyond traditional applications in the medical and pharmaceutical industries,
the growth in alternative cleanroom building products is adapting.
There are also a growing number of opportunities for cleanroom environments within the manufacturing industry where these tall-wall
systems are often utilized.
Today’s manufacturers who are looking to meet current GMPs
need cost-effective and flexible solutions. Due to the size of most
manufacturing plants, the majority of industrial cleanrooms require
extra heights and greater clear-spans so that they can accommodate
the transfer of large equipment in and out of the enclosure. Some
of these industrial cleanrooms can reach heights up to 40 feet,
requiring walls that can extend from floor to ceiling in order to fully
segregate space and provide optimal environmental control. The
PortaMax and SteelSpan extra-tall modular wall systems provide a
solution for these types of applications.
By utilizing these new extra-tall modular wall systems,
cleanroom contractors can now provide a cost-effective solution for clients within a variety of markets that are looking for
large-scale cleanroom design-build solutions that offer the
flexibility for reconfiguration as business needs change. More
information is available at www.portafab.com.
Modular Tall-Walls Satisfy the Demand for Larger Controlled Environments
Extra-tall modular wall systems provide a cost-effective solution for
large-scale cleanroom design-build solutions.