Independent self standing Cleanroom and walkable ceiling

Cleanroom Self-Standing Walkable Ceiling Project

Nicos-Mangini was involved in designing and constructing a "box in the box" cleanroom system featuring a fully self-supporting walkable ceiling without traditional roof suspension. The design chosen incorporates sophisticated architectural and engineering elements to meet stringent cleanroom requirements while maintaining structural integrity.

Core Design Concept: Box-in-Box Approach

The cleanroom was to be constructed as a self-contained environment within the larger facility structure. This independent cleanroom system stands at 15 feet in height and creates a dedicated controlled environment (CR/DR area) with a ceiling system that serves multiple functions beyond standard cleanroom requirements.

Structural Framework

The ceiling was to be supported by a reinforced steel structure rather than being hung from the building's roof. This approach differs from traditional cleanroom ceilings that typically rely on roof suspension systems. The steel framework was designed to:

• Span 25-foot room widths without any internal pillars or columns
• Support the weight of maintenance personnel walking on the ceiling surface
• Carry the additional load of fire suppression systems
• Maintain the integrity of the cleanroom environment below

Structural Challenges and Solutions

The absence of pillars in rooms up to 25 feet wide presented significant structural engineering challenges. The design addresses these through:

• Enhanced beam design with greater depth and reinforcement to handle the increased span
• Specialized connection points to distribute loads effectively across the structure
• Use of trusses or composite beams to maintain strength while minimizing material weight
• Careful calculation of deflection limits to ensure ceiling flatness and integrity

Fire Suppression Integration

The ceiling system was uniquely designed to incorporate and support fire suppression equipment. This integration means:

• The structure was calculated to bear the additional weight of sprinkler systems and associated piping
• Access points  strategically incorporated to allow maintenance of fire suppression equipment
• Design to comply with applicable fire safety codes while maintaining cleanroom classification

Functional Benefits

This self-standing walkable ceiling design offers several advantages for cleanroom operations:

• Facilitates easier maintenance access to ceiling-mounted equipment and utilities
• Provides a more stable environment with reduced vibration compared to hung systems
• Allows for complete cleanroom isolation from the main building structure
• Enables more flexible positioning of the cleanroom within the larger facility
• Supports potential future reconfiguration of the cleanroom space

The engineering requirements for this project are substantial, requiring precise calculations for load distribution, material strength, and structural integrity while maintaining cleanroom classification standards and accommodating the additional requirement of fire suppression system integration.

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