Construction Management for Large-Scale Ultra-Clean Facilities

1. Structural Characteristics of Large-Scale Ultra-Clean Facilities

This cleanroom facility adopts the internationally popular configuration of a fresh air unit (MAU) + Fan Filter Unit (FFU) + Fan Coil Unit (FCU). The circulating air for purification is driven by the FFUs, while the indoor temperature and humidity are maintained by the fresh air units and FCUs. Vertically, the space is divided into the following zones:

(1) Lower Technical Interstitial Space: With a height of 5.3 meters, its primary functions are to house dynamic equipment for gases and water supply/drainage, lay pipelines and electrical conduits, and accommodate fresh air units and FCUs. The floor is coated with epoxy self-leveling paint, and the perimeter is enclosed by metal wall panels.

(2) Production Floor: With a height of 5.4 meters, this zone serves as the core area for process rooms and equipment installation. It is designed to maintain a vertical laminar airflow. The raised access floor is installed on a grid of waffle slabs, whose surfaces are coated with water-based epoxy paint. The ceiling features a grille suspension system, partially covered with FFUs and the rest with blind panels to separate it from the upper plenum. The perimeter of the production floor is enclosed by metal wall panels to isolate it from non-clean areas.

(3) Upper Plenum (Static Pressure Box): With a height of 2.5 meters, this zone equalizes the mixed air of fresh air and return air entering from the return air shafts. The air is then pressurized and filtered by the FFUs before being delivered to the production floor. This zone also houses the automatic sprinkler system (for the production floor) and electrical systems. The upper plenum is separated from the non-purified upper steel roof structure by sandwich metal panels.

2. Three-Dimensional Cross-Construction Organization Design

Based on the overall construction schedule control plan, a master schedule for the cleanroom installation works was developed. When formulating this schedule, meeting the deadline was prioritized, followed by emphasizing the principle that "cleanliness is the core objective of all work." Given the structural characteristics, the production floor is located in the middle of the facility and serves as the core zone requiring guaranteed cleanliness. Therefore, a construction sequence was adopted: working from the outside in, installing the raised access floor first, followed by the upper plenum ceiling and the lower technical interstitial space, and finally completing the core production floor.

2.1 Work Area Zoning

The openings on the waffle slabs measure 1.3m x 1.3m, posing significant safety hazards. To address this, common utility hangers are installed beneath the waffle slabs first, followed by safety netting, and then the raised access floor is laid. After the access floor is installed, the space is divided into two working zones (above and below the 5.3m level). Separate progress plans are formulated for these two zones according to the installation schedule.

2.2 Definition of Project Control Milestones

Based on project characteristics, seven key control milestones were established: Cleanroom Commencement, Coating Completion, Raised Access Floor Completion, Grille Ceiling System Completion, Power-On, Process Equipment Move-in, and Project Completion.

2.2.1 Cleanroom Commencement

Cleanroom construction requires a sealed environment. Therefore, the prerequisite for commencement is the completion of the main building construction and the sealing of the building envelope.

2.2.2 Coating Completion

The tasks required at this milestone include: completing the coating of the waffle slabs, beams, and walls on the production floor; completing the coating of the return air shafts; finishing the installation of common brackets and safety nets; and completing the drilling for raised access floor pedestals. High-dust-generating tasks, such as drilling, must be largely completed by this milestone.

2.2.3 Raised Access Floor Completion

Tasks controlled at this milestone include: completing the installation of the raised access floor; finishing the intermediate coating in the lower technical interstitial space; commencing the installation of the upper plenum ceiling and wall panels; beginning the installation of HVAC equipment, pumps, and heat exchangers; and starting the fabrication and installation of various ducts, pipeline routing, and electrical conduits.

2.2.4 Grille Ceiling System Completion

The main tasks at this milestone include: completing the installation of the grille ceiling system and the wall panels in the lower technical interstitial space; completing the main pipeline routing for ducts and various pipes; and basically completing the electrical conduit routing.

2.2.5 Power-On Milestone

Tasks controlled at this milestone include: initiating individual power-on test runs of the air conditioning units; completing all HVAC ductwork except for insulation; and completing all HVAC piping except for pressure testing and insulation.

2.2.6 Process Equipment Move-in

At this stage, all interior finishing works must be sealed, HVAC duct insulation must be completed, pressure testing of cooling water, pure water, drainage, vacuum, and tap water systems must be finished, power connections must be completed, and lighting must be energized.

2.2.7 Project Completion

This milestone requires the completion of individual system test runs and the successful commissioning and testing of all systems.

Suzhou Pharma Machinery Co.,Ltd.

2026/08/10

Gino