Overview

Airtho was contracted to design and construct an isolated clean area within an existing office space. The goal was to create an ISO 7 clean area that integrated seamlessly with the building’s layout while utilizing existing walls, infrastructure, and conditioned plant air. The project involved building upgrades, installation of an Intelligrid™ ceiling, HEPA filtration, and final ISO certification.

Challenge

The project presented several significant challenges due to the need to construct a clean environment within a fully occupied existing building. These challenges included fitting a custom cleanroom layout into the existing room geometry, coordinating isolation upgrades using the current walls, doors, and airlock, and installing a new Intelligrid™ ceiling system within limited ceiling height constraints. Additional complexities involved meeting ISO filtration requirements with energy-efficient HEPA integration and executing all work within an active facility while minimizing disruption to ongoing operations.

Solution

• Intelligrid™ Ceiling System: A custom Airtho Intelligrid™ ceiling system replaced the standard office drop ceiling to support the Airtho HEPA Hub SD, integrated gasketing, aluminum blank panels, and high-quality cleanroom lighting..

• HEPA Filtration & Airflow Performance: To achieve ISO 7 at-rest conditions, the clean are was equipped with a 1500 CFM Airtho HEPA Hub Fan Unit, two 2’×4’ FRM media HEPA filters, a low-wall return, and adjustable makeup air damper supplied from conditioned plant air. This configuration provided over 30 ACH, ensuring consistent cleanroom performance.

• Installation & Coordination: Airtho provided turnkey installation, including ceiling removal, wall preperation and cladding, Intelligrid™ build-out and HEPA Hub placement, lighting integration, flex duct connections, baseboard installation, and finishing work. Installation was completed in under two weeks.

Results

• Fully functional ISO 7 clean area integrated into the existing facility

• Effective isolation using upgraded finishes, Intelligrid™, and HEPA Hub system

• Clean architectural fit with existing airlock and room layout

• Achieved ultra-efficient airflow performance requirements

• Completed project delivered with client satisfaction in under two weeks