Watch On Demand: Expert Insights on Cleanroom Design
Cleanrooms are designed for precision, control, and compliance—but the processes they support rarely stay the same for long. As life sciences research, advanced manufacturing, and regulatory requirements evolve, cleanroom facilities must be able to adapt. That challenge was the focus of Lab Design’s webinar, How to Build a Cleanroom, which is available to watch on demand.
Presented by Jim Levin, director of process architecture and associate principal at Perkins&Will, the free webinar offers a practical walkthrough of the entire cleanroom lifecycle. From early planning and design through construction, commissioning, and post-occupancy evaluation, the session provides a clear look at the decisions and strategies that shape successful cleanroom facilities.
One of the key takeaways is the importance of starting with the right questions. Cleanroom projects often involve multiple stakeholders—from scientists and engineers to facility managers and regulatory experts—and aligning these groups early can help prevent costly redesigns later. Levin emphasizes that clear communication about process requirements, equipment needs, and future growth is essential for building a facility that performs well both immediately and over time.
Flexibility is another central theme. Modern cleanrooms increasingly integrate automation, modular workstations, and sophisticated monitoring systems designed to improve efficiency and maintain strict contamination control. Supporting these technologies requires careful attention to infrastructure. Airflow and filtration systems, for example, must maintain the controlled environment necessary for sensitive processes, while electrical and mechanical systems need enough capacity to support both current equipment and future upgrades.
The webinar also explores how physical design decisions are often driven by the processes taking place inside the facility. Ceiling height, mechanical space, and equipment layout must all be carefully coordinated to support manufacturing and research activities.
Levin addresses this point in greater detail when responding to an audience question about cleanroom dimensions and infrastructure:
“Typical ceiling heights within cleanrooms would be 9 feet or 10 feet, depending upon the process equipment heights. Larger-scale facilities use tall tanks and equipment with ceiling heights as high as 20 feet or even 30 feet tall. So ceiling heights are driven by the process equipment. The engineering and mechanical zone above can run from 10 feet tall to 30 feet tall depending upon the size of the duct work, control systems, and air handlers needed for the spaces below. For a CAR-T cell facility, I usually start with an 18 to 20-ft. clear space for the cleanrooms and overhead mechanical zone combined. For larger facilities, I start with 36 to 40-ft. clear space and adjust upwards or downwards as informed by the equipment space height needs.”
Regulatory frameworks are another important factor shaping cleanroom design. In response to a question about pharmaceutical GMP standards in the US, Levin explains how guidance and regulatory authority differ from other regions:
“The US does not have a single standard like Annex EU. The Code of Federal Register (CFR) Title 21 regulates food and drugs, but provides no useful information about facility design or GMP standards in sections 210 or 211 that pertain to drugs. It does give the FDA the authority to promulgate these standards which they do through Guidance documents which are available online at FDA.gov. They also rely on expert organizations like ISPE to provide reliable information on how to comply with their standards.”
Beyond planning and construction, the webinar highlights the importance of evaluating a cleanroom once it becomes operational. Post-occupancy evaluation allows teams to monitor facility performance, address safety or ergonomic concerns, and identify opportunities to optimize workflows and infrastructure. This ongoing assessment helps ensure that the facility continues to support both personnel and processes effectively.
For professionals involved in life sciences, biotechnology, and advanced manufacturing, How to Build a Cleanroom provides a concise yet comprehensive overview of the strategies behind adaptable cleanroom design. Whether you are planning a new facility, renovating an existing space, or looking to better understand the infrastructure behind these highly controlled environments, the webinar offers practical insights that can inform future projects.
The full session is now available to watch on demand through Lab Design. American Institute of Architects members can earn 1 LU/HSW credit by viewing this webinar and emailing their membership number to mdidonna@labdesignconference.com.
