1、4774 Integrated Cleanroom Design and Construction Charlie C. Shieh, PhD, PE Member ASHRAE ABSTRACT The scope of integrated building design addresses the design integration of buildings and facilities among all disci- plines from project conception to final completion and handover. This paper discuss
2、es the design and construction integration ofcleanroom buildings and cleanroom facilities to achieve better qualiy, faster delivev, lower cost, more opti- mized operation and maintenance, lower energy consumption, cleaner environment, safer, more reliable and moreproductive conditions, and longer se
3、rvice life. INTRODUCTION A complete cleanroom project is usually composed of the following stages: the development of scope, budget, and over- all project execution plan stage; the pre-design, conceptual, and schematic design stage; the preliminary, final design, and construction documentation stage
4、; and the construction service stage. Figure 1 outlines the general project design and construction service procedure for a typical design, bid, build project. PROJECT SCOPE, BUDGET, AND EXECUTION PLAN To initiate a cleanroom facility project, the owners project management develops the project scope
5、, budget, and its overall execution plan. Project Scope The project scope typically covers the following aspects: Determination of the size of the cleanroom project. 1. 2. 3. 4. 5. 6. 7. 8. 9. Determination of the type of the project, such as new build- ing on new site, new phase, new building as ex
6、pansion on existing site, existing building expansion, cleanroom reno- vation in existing building, partial renovation, etc. Site investigation, site survey, and site selection. Conrmation of site conditions. Determination of the process(es) to be contained in the cleanroom facility. Establishment o
7、f design criteria. This should include issues such as cleanliness class, laminar flow velocity, air-change rates, volume of process exhaust, volume of outside air, ceiling HEPA or ULPA filter coverage, energy efficiency target (W/SF, or WCFM), cost efficiency target ($/SF), etc. Determination of pro
8、duct type and quantitative goals. Consideration of safety issues: explosion proof, corrosion proof, cross-contamination proof, fire protection, building security, etc. Determination of electricity, gas, water supply, sewer and storm drain connections. 1 O. Selection of communication systems. 1 1. De
9、termination of transportation requirements: local trans- portation and indoor conveyers. 12. Determination of control strategies. 13. Devise energy recovery methods. 14. Consideration of environmental issues: exhaust air and 15. Consideration of seismic classification and requirements of waste water
10、 treatment. seismic design. Charlie C. Shieh is a senior vice president of engineering with CYS Consulting, LLC, Bellaire (Houston), Texas. 02005 ASHRAE. 355 PROJECI SCOPE LI- I; v I Figure 1 General design and construction procedure. 16. Establishment of a list of codes, standards, and local rules
11、and regulations to be applied in the project. 17. Local community concerns. 18. Performance of constructability review. Project Budget Plan The owner?s project management will develop an initial budget plan in accordance with the project scope and the finan- cial capability and feasibility. The init
12、ial budget plan will take the project scope into consideration and set limits to the proposed project scope if it is not financially feasible. The scope and budget plan shall be adjusted and finalized with compromised alternative adjustments during the scope and budget development stage. The budget
13、will determine the quality for the project as well as the scope and schedule. They all work together. Doing things on an accelerated schedule is likely to increase cost; within the scope, there are varying quality levels that can be provided. Overall Execution Plan The project?s overall execution pl
14、an, the project?s funda- mental documentation (PFD), usually is developed by the owner?s project management but may be finalized together with a design consultant depending on the preference of the owner and the project design contract. A complete execution plan should cover the entire design and co
15、nstruction service stages. PRE-DESIGN, CONCEPTUAL, AND SCHEMATIC DESIGN STAGE Pre-Design Activities Based on the project?s fundamental documentation, the owner?s project management will issue the request for propos- als (RFP) and select and form the project design team. The fundamental documents sha
16、ll include: 1. 2. 3. 4. 5. 6. 7. Clarification of type and scope of the project Determination of type and source of financing Selection of the project site, geotechnical investigation, and site survey Clarification of site conditions Determination of project process requirements, process adjacencies
17、, cleanroom process personnel flows and process material flows, energy efficiency and environmen- tal goals, project design criteria for all disciplines, strategies of controls, interior and exterior dimensional requirements of the cleanroom building or building series, access and transportation: Es
18、tablishment of a list of codes, standards, and regulations to be used in the project and Determination of the project milestone schedule Conceptual and Schematic Design The conceptual and schematic design could either be prepared by the owner?s project management or by the 356 ASHRAE Transactions: R
19、esearch selected design team depending on the preference ofthe owner and the project design contract. The conceptual and schematic design should cover site investigation and reports, site layouts, building schematic layouts, process and instrumentation diagrams, process and facility concepts, utilit
20、y concepts, building system concepts, cleanroom system, auxiliary system and subsystem concepts, control concepts, energy analysis, environmental, fire protec- tion, security, communication requirements, and compliance with codes, standards, and local govemmental rules and regu- lations. The project
21、 cost estimate should be revisited at the conceptual and schematic design stage and must not exceed the approved budget plan. The completed cleanroom project conceptual and schematic design package should be submitted to the owner for review and approval. The project scope may be adjusted during cli
22、ent review, and the clients project management shall confirm and approve the finalized concep- tual and schematic design package as the basic document in Request for Proposals and review of submittals. Select a Design Team The design team must be capable of overseeing and conducting the entire clean
23、room project design and construc- tion service in accordance with the project scope, developing project overall execution procedure to accomplish the project within the required time period under the approved budget, including project site plans, buildings, building systems, transportation, utility
24、systems, cleanroom systems, produc- tion lines, controls, and all other related design works neces- sary to complete the project. The design team must be able to conduct site investiga- tion, prepare an investigative report with the feasibility study, and make recommendations. The design team needs
25、to coordinate among architects, engineering disciplines, equipment and material suppliers, contractors and subcontractors, client and their consultants, utility agencies, and governmental authorities. The design team must thoroughly understand and comply with applicable federal and local codes, stan
26、dards, rules, recommendations, and regulations. The design team shall observe and respond to requests from the construction team and assist the owner in expediting the construction progress, observe system start-up and testing, adjustment, and balance, may conduct training of owners operation and ma
27、intenance personnel, and supervise the project commissioning and handover to the owner. Integrated Project Team To best approach cleanroom design and construction, the following parties will perform as an integrated team to achieve project optimization: 1. Owner-responsible as owner for developer, f
28、acility management, occupants, and/or operating personnel. 2. 3. 4. 5. 6. 7. 8. 9. 1 o. 11. 12. 13. 14. Architects and engineers-provide design and construction administration services. Geo-technical-provide test and investigation report. Site surveyor-provide survey report. Utilities-involved in el
29、ectric, gas, water, sewer, flood drain planning, and services. Safety services-involved in fire protection and building security system planning and services. Transportation agencies-involved in transportation plan- ning, e.g., rail, trucking. Health and hygienic experts. Communication services -inv
30、olved in telephone, network planning and services. Government authorities-involved in code enforcement, planning and zoning, fire marshal, flood and ground data, transportation, health and hygiene, and seismic concerns. Material suppliers-supply building materials, cleanroom elements, product materi
31、als. Equipment suppliers-supply equipment of electrical, mechanical, building, HVAC, water, sewer, plumbing, fire protection, security, communication, controls, etc. Contractors and subcontractors-responsible for construc- tion and installation. Testing agencies-perform testing of geo-technical, con
32、crete, building system, cleanroom system, HVAC system; conduct adjusting, balance, and commissioning. Construct-ability Review: Construct-ability must be carefully and thoroughly reviewed throughout the entire design process by the design team project management with the coordination of the owner, e
33、quipment and material suppliers, contractors, subcontrac- tors, utility agencies, transportation agencies, environmental agencies, local communities, and govemmental authorities. PRELIMINARY, FINAL DESIGN, AND CONSTRUCTION DOCUMENTATION Preliminary Design According to the approved conceptual and sch
34、ematic design layouts and the related specifications and documents, the selected design team can then initiate the first stage of preliminary design work including site plan, building floor plans and general arrangement layouts, process and utility piping and instrumentation diagrams with the review
35、 of owners project management. The second stage ofpreliminary design would include detailed site plan layouts, building system layouts, process system layouts, building utility and process utility layouts, general calculations, cleanroom calcu- lations, ceiling HEPA filter layouts, cleanroom area pr
36、essur- ization layouts, equipment and material selections, equipment and material specifications, equipment list, electric and utility ASHRAE Transactions: Research 357 data, structure data, electric single line drawings, and control specifications. In this second stage, all inputs from existing con
37、ditions, adjacencies, and from client, vendors, utility suppliers, and governmental regulatory agencies should be addressed thoroughly and all the applicable codes, standards, and local governmental rules and regulations shall be imple- mented completely. The preliminary design drawings and specific
38、ations shall be stamped and signed by the architect and engineers and submitted to the governmental authorities for permits. Final Design and Construction Documentation After the completion of the preliminary design, the design team produces final drawings, including all necessary floor plans, secti
39、ons, details, and system diagrams, equipment schedule, material schedule, material take offs, major equip- ment purchasing bid packages, construction specifications, and construction bid packages. CONSTRUCTION SERVICE The last stage of design-team work in a complete clean- room engineering project s
40、hall include construction services and interface with construction professionals. In this stage the design team observes the project planning, construction schedule, cost-effectiveness, value engineering and best alter- natives, construction quality, system life, project safety, prep- aration or sup
41、ervision and participation of commissioning, owners operation and maintenance personnel training, system acceptance, and project handover. The scope of construction service work in a cleanroom project is based on the project contract. Usually the prepara- tion of construction documents is an essenti
42、al part of the final design package. In the final design stage, final drawings are issued together with an index that catalogs the entire final design package, including drawings, specifications, and addenda if applicable. Depending on the clients preference specified in the contract, the design tea
43、m may also prepare a complete construction and installation bid package that includes the final drawings and specifications and may also include an announcement or advertisement, addenda, clarifi- cation of bid conditions, a schedule of bidding, bid document distributions, and bid instructions. Duri
44、ng the bidding stage, contractors and subcontractors must review all design plans, specified requirements, addenda, and bid instructions and determine their ability to perform and accomplish the project. Any issues or concerns should be promptly discussed with the related design architect or design
45、engineer and related personnel to determine the best alterna- tives. Once the bids are received, the design team begins the process for submittal review, evaluation, value engineering, recommendation of contractors and subcontractors, owner review, approval, awarding of contracts and subcontracts. T
46、he final step of the cleanroom project construction service shall be on-site observation and investigation, includ- ing a periodic construction quality report, technical analysis and solutions, observation of system start-up, test, adjustment, and balance, verification of room pressurization and cle
47、anli- ness, training of the clients operating and maintenance personnel, issuance of operation and maintenance manual, coordination of the project commissioning, and handing over the completed project to the owner. POST-DESIGN AND CONSTRUCTION OPERATIONS Post-design and construction operation and ma
48、intenance are the last essential stage of the cleanroom project and the key to maximizing the efficiency, productivity, and service life of the cleanroom facility. As the final and integral part of the project team, the owner needs to be familiar with the facility systems performance capabilities an
49、d limits, constantly monitor system operation, keep routine records, and provide scheduled maintenance in accordance to the operations manual. BUILDING AS A SYSTEM In summary, although the entire cleanroom building project is a large and complex operation, it may be simplified if it is considered as an integrated system with unified overall scope of work and unified timeline schedule to be performed and achieved by an integrated design and construction team. In this integrated system, all individual systems and their compo- nents should be considered as subsystems of the overall int
