In industries where contamination control is critical—such as pharmaceuticals, electronics, biotechnology, and food processing—the role of clean rooms cannot be overstated. Clean rooms are designed to maintain strict environmental conditions, including air cleanliness, temperature, humidity, and pressure. One of the most efficient and cost-effective ways to construct these environments is by using Sandwich PUF (Polyurethane Foam) Panels, known for their thermal insulation, durability, and ease of installation.

Sandwich PUF Panel Clean Room consist of a polyurethane foam core sandwiched between two metal sheets, typically pre-coated GI (galvanized iron) or stainless steel. These panels offer excellent structural stability and can be customized to meet ISO clean room classifications. Whether you’re setting up a small modular unit or a large-scale clean room facility, following a structured installation process ensures long-term performance and compliance with industry standards. In this comprehensive, step-by-step installation guide, we’ll walk you through the process of setting up a clean room using sandwich PUF panels—from initial planning to final sealing and system integration.

Essential Steps Must Be taken for Sandwich PUF Panel Clean Room

Step 1: Pre-Installation Planning

Before the physical installation begins, it’s vital to plan every aspect of the clean room build.

Key Activities Include:

Site Survey: Examine the location for dimensions, layout, access, and any obstacles.
Design Layout: Finalise the clean room layout, taking into account airlocks, HVAC s ystems, electrical conduits, and work areas.
Compliance Checks: Review ISO or GMP clean room classifications and ensure your design meets the required standards.
Material Check: Confirm the availability of sandwich PUF panels, doors, viewing windows, and other accessories.

Pro Tip: Work with experienced clean room specialists during this phase to minimise costly design errors later.

Step 2: Site Preparation

Activities Involved:

Surface Cleaning: Clean the floor thoroughly to remove dust, oil, and debris.
Levelling: Ensure the base is level using self-levelling concrete or epoxy if necessary.
Marking: Draw guidelines on the floor based on the approved layout.

Note: A well-prepared site ensures precise panel alignment and structural integrity.

Step 3: Panel Unloading and Storage

Handling Best Practices:

Unload Carefully: Use cranes or forklifts to avoid panel damage.
Storage: Keep the panels in a dry, shaded, and flat area to prevent warping.
Inspection: Check for dents, scratches, or manufacturing defects.

Proper storage and handling at this stage ensure the panels remain in optimal condition throughout the installation.

Step 4: Floor Track Installation

Install aluminium or stainless-steel tracks on the floor of the Sandwich PUF Panel Clean Room as guides.

Steps:

Align the tracks along the marked layout.
Secure them with fasteners and anchors.
Seal the edges with silicone to avoid air and particle leakage.

The floor track acts as the foundation and must be fixed with high precision.

Step 5: Erection of Wall Panels

Installation Sequence:

Insert the bottom of the panel into the floor track.
Use cam-lock mechanisms or joinery profiles to interlock adjacent panels.
Fasten the top edge to the ceiling frame or support grid.
Check vertical alignment with a spirit level.

Repeat the process for all wall panels. For doors and windows, insert cut-out panels or frames in the designated positions.

Step 6: Ceiling Panel Installation

The clean room ceiling plays a key role in housing HEPA filters, lighting, and HVAC ducts.

Instructions:

Use hanging rods or ceiling grid supports to suspend the ceiling panels.
Fit and lock each panel tightly to ensure a seamless air barrier.
Leave provisions for lights, filters, and air conditioning vents.

Tip: Coordinate with HVAC and electrical teams before final ceiling placement.

Step 7: Door and Window Integration

Doors and vision panels are integrated within the PUF panel structure.

Steps:

Place pre-fabricated clean room doors in designated wall cut-outs.
Fix viewing windows using silicone sealants or rubber gaskets.
Check for proper alignment, lock mechanism, and air-tight sealing.

Use flush doors for better hygiene and easy cleaning.

Step 8: Corner Finishing and Joint Sealing

To achieve a contamination-free zone, all joints and corners must be sealed meticulously.

Materials Needed:

Clean room-grade silicone sealant
PVC coving or aluminium profiles
Masking tape for clean edges

Apply sealant generously on all joints—vertical, horizontal, and around fixtures. Allow it to cure as per the MGPS in Raipur Chhattisgarh recommendation.

Step 9: HVAC, Lighting, and Electrical Work

After panel installation, MEP (Mechanical, Electrical, and Plumbing) systems are integrated.

Install:

HEPA Filters: Mounted on ceiling panels with filter grids.
Lights: Use LED flush-mounted fixtures for minimal particle disturbance.
Air Conditioning: Integrate AHUs and ducting to maintain air quality and temperature.
Sockets & Switches: Install using concealed conduits within the panels.

Ensure: All penetrations are sealed with gaskets or silicone to maintain the clean room’s integrity.

Step 10: Validation and Testing

Once the physical structure and systems are installed, perform rigorous testing to validate clean room performance.

Key Tests Include:

Airflow & Pressure Differential Test
HEPA Filter Leak Test
Particle Count Test
Temperature & Humidity Control Test

Documentation of these tests is crucial for GMP or ISO certifications.

Step 11: Final Clean-Up and Handover

Clean all surfaces with an approved disinfectant and perform a detailed handover with operational manuals, maintenance instructions, and warranty documents.

End Notes

Constructing a Sandwich PUF Panel Clean Room is a precise and demanding task, but with the right planning, tools, and execution, it can be achieved efficiently and affordably. From initial design to final validation, every step plays a vital role in delivering a contamination-controlled environment.If you’re looking for high-performance clean room panels and end-to-end installation services, look no further than Unique Medical Gas Solutions. As an industry leader in clean room solutions and sandwich PUF panel technology, we provide exceptional quality, expert support, and reliable products tailored to your specific needs. Make your clean room setup seamless and standards-compliant—partner with us today.

MGPS