Building a Cleaner Cleanroom: Best Practices and Emerging Trends

Cleanrooms are the backbone of the most environmentally sensitive industries, where even the tiniest contaminant can disrupt research, production, or patient safety. As standards tighten and demand grows, designing and building cleanrooms that meet today’s rigorous requirements takes careful planning and innovation.

From advanced airflow systems to prefabrication, the industry is evolving to create cleaner, more efficient spaces. To ensure the execution of a seamless and contamination-free environment, these considerations must start early in the construction process.

Laying the groundwork for cleanroom success

A functional cleanroom starts with smart planning. Every decision, from site selection to choosing materials, directly impacts contamination control and its day-to-day operation. Using low-emission materials, seamless wall systems, and non-porous surfaces minimizes particle buildup, while strategic integration of mechanical systems ensures precise airflow, pressure control, and filtration. By addressing these factors early in the design process, teams can create an environment that will prevent contaminants from becoming an issue even before construction begins.

DPR Construction’s work on Theragent’s cell and gene therapy facility highlights the importance of these principles. The project required an ISO Class 7 cleanroom to support both personalized medicine and high-volume manufacturing while adhering to strict current Good Manufacturing Practices (cGMP). By leveraging modular cleanroom components and off-site prefabrication, the team reduced contamination risks and accelerated construction timelines.

The power of early collaboration

Bringing project teams together early is essential to building a cleanroom that performs as expected and stays on schedule. When mechanical, electrical, and plumbing trade partners are involved directly after approval of the basic concept design, they can coordinate efforts and develop a plan that allows every trade to work efficiently both independently and collaboratively. This level of upfront planning ensures that critical systems are coordinated upfront and installed smoothly, avoiding costly adjustments later in the process.  

It’s also important to consider collaboration tools, such as Building Information Modeling (BIM), to help teams integrate design models, cost estimates, and system layouts in one place. By working from a nearly clash-free model before construction even begins, projects stay on schedule and avoid costly rework in the field.  

Virtual design tools like laser scanning, 4D visual planning, and aerial capture also help improve efficiency and safety by providing a clear picture of site conditions. Automated technology can further enhance accuracy and remove guesswork.   

By prioritizing collaboration from the start, teams can identify challenges before they become a crisis and prevent construction from moving forward. They can also establish convenient work and shut-down schedules to limit disruptions to business. A well-planned cleanroom is not just about meeting technical requirements. It is about delivering a space that supports critical work from day one.

Rethinking cleanroom construction with prefabrication 

Prefabrication is defining a new approach in cleanroom and biotech construction. By building components in a controlled environment off-site, teams can ensure higher quality, reduce contamination risks, and streamline installation. Prefabricated wall panels, pre-assembled HVAC systems, and modular ceiling grids allow for parallel workstreams, reducing project timelines while maintaining compliance.

On the Theragent project, DPR used prefabricated cleanroom panels to fast-track construction while maintaining the highest quality standards. These modular elements were designed, tested, and verified off-site before arriving at the job site, helping to shave time off the schedule while ensuring regulatory compliance.

Different prefabrication approaches fit different facilities. It’s important for project teams to look at the individual aspects of their buildings to find the best fit. 

Building for safety and sustainability 

Cleanroom construction requires careful attention to both safety and sustainability. Research shows that 94 percent of engineers and contractors have seen client requests to reduce embodied carbon in projects. Selecting energy-efficient HVAC systems and low-emission materials helps meet these demands while maintaining cleanliness standards. Contractors play a key role in this process, leveraging product databases and experience to identify the right materials at the right cost. At the same time, precision techniques like vibration monitoring and air quality control protect sensitive equipment and ensure compliance. Integrating these principles early creates cleanrooms that support both operational efficiency and environmental responsibility.

What’s next for cleanroom construction? 

As we look to the future, cleanroom construction is poised for significant advancements. We anticipate seeing more intelligent technologies, sustainable materials, and increased use of prefabrication and other construction methods. While cleanliness standards tighten, the industry must be ready to adapt. And that all starts from day one. By working together and anticipating changes, we can optimize project needs early and build the next generation of cleanrooms.