Terra's Hybrid Modular Rooms are both flexible and scalable, accommodating a variety of utility connections including compressed gas, vacuum, plumbing, phone, and Ethernet lines. This flexibility ensures that the wall systems can be tailored to specific operational needs, making them suitable for a wide range of cleanroom applications. Hybrid design includes interlocking honeycomb wall panels lined with a uPVC substrate on the interior and exterior. Extruded aluminum side pieces allow each panel to interlock, with the gaps filled in with silicone sealant.

A major selling point of traditional modular cleanrooms is to consolidate the sourcing, fabrication, and delivery of construction materials into a streamlined, simplified process. These systems are quick to return an ROI due to the speed, ease, and repeatability of the construction process. Modular systems offer peace of mind and guaranteed compliance of the final assembly with ISO cleanliness requirements.

Terra's modular cleanroom panels arrive from the factory with prespecified cutouts for pass-throughs, doors, and windows, which eliminates most on-site modifications that would otherwise require sawing, cutting, or drilling. Importantly, modular components and panels can be easily swapped out, relocated, or replaced without requiring complete shutdown of the cleanroom operation. Modular construction compresses the entire enclosure into flat packed, palletized shipment. With the help of a fork lift, a team of 3 - 5 installers can erect the entire enclosure within a couple of days, if not less, depending on the size and number of wall partitions required. Meanwhile, traditional framed wall builds might take several different contractors weeks or months to complete. 

Modular cleanroom systems have some clear advantages over traditionally built systems, however, there are also some limitations of modular builds that may require compromises and trade-offs. Conventional modular systems typically incur higher initial expenses and longer lead times compared to stick-built assemblies.

Further, traditional modular wall panels require extruded aluminum or stainless steel frame affixed by metal screws, which leaves hard-to-clean gaps that collect dust, contaminants, and bacteria. Modular wall systems don’t include space to run electrical connections, plumbing lines, networking cables, and gas connections. Therefore, all exposed lines on walls or columns require contamination-prone conduit coverings throughout the interior.

For modular cleanrooms, empty ceiling bays that are not occupied by fan filter units or lights require cleanroom-grade, 2’ x 4’ cover titles with ISO-rated plastics; usually polypropylene, PVC, or acrylic. Lightweight ceiling panels are frequently dislodged during spray-down and disinfection cycles, thus creating burdensome repair work.

Design freedom, customization, and unlimited spans are key benefits for stick built cleanrooms. Unlike modular designs, traditional stick built enclosures allow for unique room geometries with wider wall to wall spans at no limitations on the maximum ceiling height.

The traditional construction industry has a well-established base of skilled labor, contractors, and professionals. This widespread expertise means that finding experienced workers and resources for conventional construction projects is generally easier.

Certain applications prefer stick-built designs, whereas other industries commonly opt for modular systems. For cGMP-compliant drug discovery and USP <797> drug compounding operations, stick-built designs are a common choice, given the ease of installing coved flooring, spray-down resistant wall and ceiling panels, and the ability to hide plumbing lines and electrical cords. 

Conventional stick-built designs generally allow for the lowest upfront cost per square foot when compared to other build styles, but incur the longest installation timeframes, which is further exacerbated when on-site alterations require highly skilled laborers to complete the construction. Traditional stick-built cleanrooms carry higher operational and maintenance costs, due to annual repair costs.

Traditional framed wall builds might take several different contractors weeks or months to complete. Unlike modular construction, where components are made in a controlled factory setting, stick-built construction is more prone to human error and inconsistencies. Importantly, certain materials like drywall are prone to mold and mildew growth in moist conditions, and applications requiring humid environments, like vivariums, animal husbandry, and cell culture research often resort to modular systems.