Overview

Airtho was contracted to design and construct an isolated clean area within an existing office and laboratory environment. The goal was to create a positively pressurized ISO 7 space 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 required constructing a clean environment within fully occupied, existing building conditions. Key challenges included:

• Fitting a custom cleanroom layout into the existing room geometry

• Coordinating isolation upgrades using existing walls, doors, and airlock

• Implementing a new Intelligrid™ ceiling system inside a limited-height space

• Ensuring proper HEPA filtration airflow while maintaining positive pressurization

• Executing work efficiently in an active facility with minimal disruption

These constraints required precise design coordination and an installation sequence adapted to the unique site.

Solution

• Cleanroom Architecture & Finishes: Airtho upgraded the existing room utilizing non-shedding epoxy coatings on existing walls and doors, NUDO wall cladding applied throughout defined areas, and integration of existing flooring and architectural components.

• Intelligrid™ Ceiling System: A custom Airtho Intelligrid™ Light-Duty (LD) ceiling system was installed, including 4'×4' gasketed ceiling grid, LED flat-panel lighting, and threaded rod hanger system coordinated with existing structure.

• HEPA Filtration & Airflow Performance: To achieve ISO 7 at-rest conditions, the clean are was equipped with one 3000 CFM Airtho HEPA Hub Fan Unit, two 4’×4’ FRM media HEPA filters, a low-wall return directly connected to the HEPA Hub, and adjustable makeup air damper supplied from conditioned plant air. This configuration provided over 65 ACH, ensuring consistent cleanroom performance.

• Installation & Coordination: Airtho provided turnkey installation, including ceiling removal, wall prep, and cladding, Intelligrid™ build-out and HEPA Hub placement, lighting integration, flex duct connections, baseboard installation, and finishing work. Installation was completed in a single coordinated phase per the project plan.

• Certification & Testing: This project concluded with third-party testing to verify ISO 7 cleanliness at rest and positive pressure to surrounding space.

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 positive pressurization and airflow performance requirements

• Completed project delivered with client satisfaction and certification approval