Analysis of difficulties in the construction of prefabricated medical clean engineering
Prefabricated cleanroom engineering transforms projects into products, featuring five key characteristics: customized industrial production, rapid on-site assembly, adaptable spatial functions, environmental friendliness, energy conservation, and cost savings.
Construction is transformed into integrated, integrated units, utilizing a modular, modular, and standardized design to ensure the safety and quality of cleanroom construction and operation.
Compared to traditional on-site installation of cleanroom projects, prefabricated cleanroom engineering offers advantages such as stable and controllable quality, generally higher quality, shorter construction cycles, minimal overlap, lower construction costs, a favorable construction environment, easy upgrades, and a high level of intelligence. Cleanroom upgrades are simple and convenient, and generally do not affect the operation of surrounding units during upgrades.
Each functional unit ensures that a range of micro-parameters related to hygiene and air purification technology, such as airborne dust particles, bacterial concentration, wind pressure, wind speed, temperature, humidity, and noise, fully meet the requirements of modern cleanrooms.
I. Components of Prefabricated Cleanroom Engineering
Prefabricated cleanroom engineering primarily consists of three components: the enclosure structure, the purification system, and supporting facilities. The cleanroom envelope typically consists of a prefabricated aluminum alloy frame with airtight ceilings and walls constructed of composite panels and conductive flooring.
The purification system, or air purification and treatment system, consists of a clean air supply unit, a clean air conditioning unit, supply and return air ducting, and an air conditioning system.
Ancillary facilities vary depending on the cleanroom type, primarily including electric induction airtight doors, built-in stainless steel instrument cabinets, built-in film viewing lamps, built-in warming and cooling cabinets, built-in control panels, medical gas outlets, built-in power supply modules, related control systems, and supporting software. Basic cleanroom facilities include a pendant, shadowless lamp, operating table, anesthetic gas exhaust system, warming and cooling cabinets, leakage detection and protection devices, weak current systems such as intercoms and background music, and multimedia systems.
II. Technical Requirements for Prefabricated Cleanroom Engineering
In addition to meeting the basic technical requirements for the relevant cleanroom, the components and facilities of prefabricated cleanroom engineering must also meet the requirements for the envelope framework, envelope paneling, connectors and adapters, and seals. The components and facilities of prefabricated cleanroom projects should meet the medical process requirements of the functional area and achieve their intended functions. They should also comply with relevant cleanroom technical standards and acceptance criteria. The location of related supporting equipment, such as vent locations, gas panels, circuit interfaces, and cabinets, can be flexibly adjusted according to user requirements. The enclosure structure and supporting facilities should be standardized, modular, integrated, and integrated, with components available in a variety of specifications and a certain degree of flexibility. Factory-produced and assembled on-site, the modular structures are supported by a customized framework, with composite panels and related equipment assembled to form the ceiling, walls, and floor, creating a self-contained, removable, and adjustable enclosure.
The framework should be prefabricated and strive for commercialization, allowing for flexible assembly. The frame’s deformation tolerance must meet national standards, ensuring sufficient strength and rigidity, and the surface treatment must meet relevant requirements. The surface of the enclosure composite panels should comply with the requirements of the “Technical Guidelines for the Application of Sandwich Panels in Cleanroom and Related Controlled Environment Enclosure Structures.” The base material should preferably be metal or resin sheet, and the base material should be Class A non-combustible material. When used as exterior walls and ceilings, the surface should be free of cold bridges and condensation during use. To meet special requirements such as radiation protection and electromagnetic shielding, the enclosure modules should be custom-made and prefabricated as an integrated unit.
Adapters and connectors used in the enclosure structure should be sufficiently reliable and have sufficient load-bearing capacity. Joints between walls and ceilings, walls and walls, and ceilings should be structurally sound to ensure sealing and prevent cracking. They should be easily disassembled and restored for cleaning, inspection, and testing. All removable connectors should be easily reconnected and tightened manually after disassembly. Joints are generally sealed with embedded materials. The smoke toxicity safety level of the sealing material must be no less than ZA2 as specified in the “Hazard Classification of Smoke Generated by Materials” (GB/T 20285-2006). The sealing material must be self-extinguishing, with a self-extinguishing time of no more than 5 seconds. Gaps between enclosures, gaps formed by fixings or penetrations in the enclosures, and interfaces between various pipes, wiring, and enclosures must be sealed. Sealing between doors and door frames, cabinets, control panels, and other components must comply with the requirements of the current national standard, “Cleanroom Construction and Acceptance Specifications,” GB 50591. The sealing strip tolerance must be ±0.3mm, with a shrinkage rate of no more than 0.5%. The sealing strip must exhibit elastic recovery.
III. Difficulties in Prefabricated Cleanroom Construction
The challenges of prefabricated cleanrooms include high initial investment, reliance on the supplier’s technical capabilities, and challenges with transportation and on-site installation. High-quality aluminum profiles, FFUs (fan filter units), and sealing systems are costly, especially for large-scale projects, where cost advantages are limited. Design and construction must be integrated, requiring suppliers with experience in medical cleanroom construction. Otherwise, problems such as insufficient airtightness and irrational airflow distribution are likely to occur. Hospital needs vary, and complete standardization cannot meet specific requirements. Suppliers must possess the ability to flexibly adapt.
Large-scale components are limited in transportation, and some modules (such as the integrated static pressure box) must be shipped in sections and assembled on-site, increasing installation complexity. On-site precision requirements, such as floor flatness and wall verticality, must be strictly controlled, otherwise airtightness and cleanliness levels will be compromised.
After long-term use, bolts and sealing strips may deteriorate and require regular maintenance. Future upgrades to higher cleanroom standards (such as from Class 10,000 to Class 100) require an assessment of whether the existing structure can support these requirements. Domestic standards are still evolving. While the “Cleanroom Construction and Acceptance Code” (GB 50591) already covers some prefabricated requirements, specific standards for medical cleanrooms still require refinement.
IV. Future Development Trends
Future prefabricated cleanroom projects will incorporate BIM (Building Information Modeling) to optimize modular design and employ robot-assisted installation. The promotion and application of new materials such as antimicrobial coatings and self-cleaning panels will improve the safety of operating room environments. The development of more flexible splicing methods to meet the needs of hospitals of different sizes will gradually enhance modularity and scalability.https://youtu.be/M9Vhl-1bm-k?si=BmnDWUA1gdt8TGiq
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