Hybrid Cleanroom Construction by Terra Universal
Terra Universal's Hybrid Modular Biosafe® Cleanroom System combines modular design principles with precision-cut prefabricated wall panels. Terra's hybrid cleanroom construction offers the ease of modular install and assembly without sacrificing design freedom. Hybrid solutions are not limited by overhead clearance, size, shape, or pathways within the site. Seamless transitions between ceiling, walls, and floors ensure an air-tight, closed system to meet ISO 5 - 8 classes, GMP A-D, GLP, ASTM, and IEST requirements. Terra's Hybrid Cleanroom system utilizes interlocking honeycomb wall panels lined with a uPVC substrate on the interior and exterior. Extruded aluminum side pieces allow each panel to interlock, with the gaps filled in with silicone sealant.
Hybrid Cleanrooms: Modular Components with Stick-Built Advantages
When compared, Terra's innovative BioSafe Hybrid Cleanrooms emerge as a compelling alternative that combines modular components with stick-built advantages and customization. For companies considering the construction of a cleanroom, there are three primary design options: stick-built (conventional construction), modular construction, and hybrid modular. Each design methodology has distinct benefits; certain applications favor one design over the other, given the specific criteria for industry compliance. Before making a decision, it is important to consider certain design challenges that are inherited by traditional modular and stick-built systems.
Hybrid Modular Designs for Accelerated Builds
A major selling point of traditional modular cleanrooms is to consolidate the sourcing, fabrication, and delivery of construction materials into a streamlined, simplified process. These systems are quick to return an ROI due to the speed, ease, and repeatability of the construction process. Modular systems offer peace of mind and guaranteed compliance of the final assembly with ISO cleanliness requirements.
Terra's prefabricated cleanroom wall panels arrive from the factory with prespecified cutouts for pass-throughs, doors, and windows, which eliminates most on-site modifications that would otherwise require sawing, cutting, or drilling. Modular construction compresses the entire enclosure into flat packed, palletized shipment. With the help of a fork lift, a team of 3 - 5 installers can erect the entire enclosure within a fraction of the time required for conventional cleanroom construction. Meanwhile, traditional framed wall builds might take several different contractors weeks or months to complete.
Hybrid Wall Systems
Hybrid wall system features pre-fabricated coving panels to accommodate wall-to-floor and wall-to-ceiling conversions, free of cracks, crevices, gaps.
Hybrid Ceilings
Hybrid ceilings are composed of robust, rugged components capable of handling daily spray-down cycles.
Hybrid Materials
BioSafe Hybrid rooms are constructed from rugged, durable, and hygienic ISO-rated materials resistant to scratches, dents, and corrosion.
Recessed Channel Bases & Utility Plenums
All panels are installed onto an adjustable height, recessed channel base to ensure a level and flush interface between the wall and the finished floor. Pre-formed corner pieces eliminate the need for surface capping or flashing. Suitable for operating temperature up to 60 degrees Celsius, the pre-fabricated, progressive wall panels are lightweight, cost-effective, and easy to install. The wall panels include a plenum space to house utility and filling lines, providing the user with convenient access to gas, vacuum and water connections, along with duplex outlets, control panels, and phone jacks.
Walkable Hybrid Ceiling System
Terra’s BioSafe Hybrid Modular Ceiling System is composed of the same pre-engineered, pre-fabricated panels featured in our BioSafe Hybrid wall system, ensuring seamless wall-to-ceiling integrations. The ceiling panels are available with standard cutouts for HEPA-filtered fan units, lighting, sprinkler heads, video cameras, fire alarms, electrical drop, and gas penetrations. The entire ceiling system is walkable, allowing for easy access to equipment installed above the cleanroom and streamlined maintenance operations, such as HEPA filters change-outs. The ceiling panels maintain a flush, seamless surface for easy wipe-down or spray-down. The ceiling system is self-supported or suspended using a turnbuckle and hanger assembly, eliminating the need for a t-grid structure. The ceiling panels meets cGMP, GLP, ISO 14664-1 and ASTM standards.
Seamless uPVC Panels
Terra’s BioSafe Hybrid Modular Wall Panels are composed of an aluminum honeycomb core encased in a uPVC-laminated steel shell. The 2” thick panels adhere to ISO 14644-1 standard for ISO class 5 and below environments. The uPVC laminate finish ensures a fully flush surface that is robust, easy to clean, and resists common disinfectants, acids and corrosives. Seamless transitions between the ceiling, walls, and floors ensure an airtight, closed system to prevent contamination influx.
Explore End to End Services & Solutions
Architecture & Lab Planning
Terra's architectural services offer a dedicated resource when designing large scale facilities with multiple suites, or cross functional spaces that combine cleanrooms, labs, gowning rooms, processing areas, offices, and parallel working spaces.
Validation & Commissioning
When a facility design must meet AAALAC, CDC, CGMP, and GLP standards, it is essential to avoid design compromises that hinder the flow of materials, personnel, and products.
Consulting & Expertise
Our teams comprise decades of expertise in healthcare and pharmacy administration, FDA regulated facilities, issues management, risk management, modeling of healthcare delivery, and safety-quality improvement.
Get a Cleanroom Consultation
Terra offers fully integrated cleanroom engineering design, architecture, construction, and system integration. Rest assured, you'll have a single point of contact for delivering a complete solution.
Ask a Terra Cleanroom Specialist
Contact Terra Universal
As a pioneer in the critical environment industry, Terra Universal has developed and manufactured innovative solutions for over 45 years. Combining high-throughput, automated fabrication equipment with a robust, active stock of raw materials, Terra is capable of producing cleanrooms of any design, size, scope, and complexity at industry-leading build times.
