Clean room ventilation

Order design and installation of clean room ventilation

Design of ventilation systems

Design begins with a technical survey of the facility and development of the assignment. Technical Department engineers – including Aleksandr Aleksandrovich Semenok and Lyubov Ivanovna Korzhuk, head of the VET – carry out air exchange calculations, equipment selection and development of a working flow control scheme. Depending on the cleanliness class and technological requirements, it is designedcentral, local or unidirectional type of system, including direct air supply without recirculation. Integrated design covers supply and exhaust circuits, automation units, as well as engineering solutions for integration with heating systems. All documentation is developed in accordance with GOST and ISO, which regulates permissible particle concentrations and microclimatic parameters.

Installation and installation of equipment

Installation is carried out by our own teams using equipment of our own production (Temirtau, 2 workshops with an area of over 1000 m², CNC machine park). Supply and exhaust units, air ducts, HEPA and ULPA filters are installed strictly in accordance with the approved working documentation. This eliminates deviations that are critical during the operation of clean zones. After installation is completed, tests are carried out: monitoring pressure, flow rate, temperature and humidity. Installation dates are agreed upon individually based on the volume and complexity of the facility – typical production plants with an area of ​​500 m²+ are put into operation in stages without stopping related processes.

Individual calculation and selection of solutions

Maintenance and repair of ventilation systems

After commissioning, ABL Engineering Group providesscheduled maintenance and repairs mounted systems. Routine maintenance includes replacing HEPA/ULPA filters, checking the tightness of air ducts, calibrating pressure and microclimate sensors, and monitoring the operation of automatic controls. If deviations are detected, the team leaves within the agreed time frame. This approach reduces the risk of microbiological contamination and non-compliance during routine inspections. The terms of service are fixed in the contract – the client receives clear regulations and guarantees of maintaining the specified cleanliness parameters for the entire period of operation.

Portfolio: among the implemented objects are ArcelorMittal production sites, pharmaceutical workshops, laboratory buildings and warehouse complexes. Dozens of completed projects confirm the team’s experience in working with objects of increased technical complexity.

Ensuring high levels of air purity and reducing pollution risks

Air quality and pollution control are not an abstract KPI, but a direct condition for the safety of the technological process. In pharmaceutical production, operating units, microelectronic workshops and laboratories, even a short-term excess of the permissible concentration of particles or microorganisms leads to product defects, line stops or sanctions from regulatory authorities. This is why cleanroom ventilation is designed as a risk management system, and not just as a utility service.

Air quality and microclimate monitoring

Air quality control in controlled areas covers several interrelated parameters: the concentration of suspended particles, the content of microorganisms, temperature, humidity and pressure drop between adjacent rooms. Deviation of any of them takes the room out of the cleanliness class provided for by the project.

ABL Engineering Group engineers, when developing clean room ventilation systems, incorporate multi-stage air flow purification – from coarse filters at the inlet to the final stages based on HEPA and ULPA filters. This approach provides:

• Particle removal from 0.1 microns in size with efficiency corresponding to ISO 14644 cleanliness class;
• Reduced concentration of microorganisms up to standard values established for a specific cleanliness class;
• Stable microclimate— maintaining specified temperature and humidity ranges without jumps that are critical for biological and chemical processes;
• Controlled differential pressure between zones, preventing the flow of polluted air into clean zones.

Automation systems integrated into the project conduct continuous monitoring and record deviations in real time – this is a prerequisite for compliance with sanitary and technical standards during inspections.

Minimizing the risks of contamination and non-compliance

The risk of contamination and microbiological contamination in clean rooms is systemic: it arises not only from external sources of harmful substances, but also from design errors in the ventilation system itself. Incorrectly calculated air exchange rate, incorrect flow distribution scheme or untimely replacement of filters – each of these factors creates a real danger for the technological process and personnel.

Consequences of non-compliance with GOST and ISO standards include:

1. Product recalls and financial losses due to microbiological contamination of batches;
2. Instructions and fines from the Committee for Sanitary and Epidemiological Control of the Ministry of Health of the Republic of Karelia, pharmaceutical inspectorates and industry regulators;
3. Stopping production for the period of elimination of violations – with direct losses of revenue;
4. Reputational damage when working with international partners who require confirmed compliance with ISO 14644 and GMP standards.

ABL Engineering Group achieves these risks through a set of technical and organizational measures:

Position of ABL Engineering Group engineers: compliance with sanitary and technical standards is laid down at the design stage, and is not corrected after installation. Each project undergoes an internal examination by specialists from the Technical Department – this allows us to identify potential inconsistencies before the start of construction and installation work.

The complexity and criticality of cleanroom ventilation problems require not universal solutions, but engineering calculations for a specific facility. ABL Engineering Group – operating since 2009, 40+ completed projects, own equipment production in Temirtau – has the resources and competencies to ensure systems meet the requirements of the customer and regulators throughout the entire life cycle of the facility.

Technical characteristics and equipment for ventilation of clean rooms

The effectiveness of a cleanroom ventilation system is determined not only by the air distribution scheme, but also by the precise selection of each component – from filters to automation equipment. ABL Engineering Group designs and supplies equipment of its own production (Temirtau, 2 workshops with an area of ​​over 1000 m², CNC machine park), which ensures full quality control at every stage. Below are the key technical characteristics and components that determine the cleanliness class and reliability of the system.

HEPA and ULPA filters

Final air purification in clean rooms is implemented through class filtersHEPA(H13–H14) andULPA(U15–U17). The difference is fundamental:

• HEPA retain at least 99.95–99.995% of particles with a size of 0.3 microns – used in rooms of ISO classes 5–8 (GOST classes 100–100,000).
• ULPA provide efficiency from 99.9995% on particles from 0.12 microns – critical for ISO classes 3-4, pharmaceutical and microelectronic production.

The choice of filtration class is determined by the calculation of the permissible particle concentration, the requirements of technological regulations and ISO 14644 / ISO 14644 standards.Semenok Alexander Alexandrovich andHead of the Technical Department Korzhuk Lyubov Ivanovna— calculate the air exchange rate and select filter elements for a specific technological process of the facility.

Equipment components and automation

The cleanroom ventilation system is a complex of interconnected units, each of which affects the final microclimate parameters. Key components and controlled characteristics:

Parameters that the system supports automatically:

• Temperature— stabilization in the range specified by the technological regulations (usually 18–22 °C).
• Humidity— control of relative air humidity, critical when working with hygroscopic materials or biological objects.
• Pressure— creation of backwater (excess pressure) or vacuum depending on the class of the room and the risks of cross-contamination.
• Flow rate and volume— ensuring the standard air exchange rate (from 20 to 600 times/hour depending on the ISO class).

Automation of ventilation systems is implemented on the basis of controllers with the possibility of integration into the general SCADA system of the facility. Automatic control devices provide:

1. Continuous monitoring of all microclimate parameters in real time.
2. Automatic control of the performance of fans and air conditioners based on sensor signals.
3. Alarm when parameters go beyond acceptable limits.
4. Keeping an event log is a mandatory requirement when certifying premises according to GMP and ISO 14644.

ABL Engineering Group position: Our own production of air ducts and housing elements in Temirtau allows us to produce non-standard configurations for a specific facility without depending on the timing of external suppliers. Over the years of work and more than 40+ specialized facilities, a database of standard solutions has been accumulated, which reduces design time and reduces the risk of errors when selecting equipment.

Prices, tariffs and commercial conditions for ventilation of clean rooms

The cost of cleanroom ventilation systems is determined individually: the final figure is influenced by the cleanliness class, area of the facility, equipment composition, design stage and volume of installation work. ABL Engineering Group does not publish fixed price lists – this is a conscious position and not an evasion of transparency. A commercial proposal without calculating air exchange parameters, air duct diagrams and HEPA/ULPA filter specifications would be technically incorrect and would mislead the customer.

We work with industrial facilities of any scale in the B2B segment. Clients include ArcelorMittal, manufacturing companies, pharmaceutical and food plants. Implemented since 200940+ objects throughout Kazakhstan: Almaty, Astana, Temirtau, Shymkent, Aktobe and other regions.

What does the cost consist of?

• Design— development of technical documentation, calculation of air exchange rates, selection of air distribution schemes, coordination with GOST and ISO standards. The scope of work depends on the cleanliness class of the room and the complexity of engineering solutions.
• Equipment— fans, heat exchangers, HEPA and ULPA filters, air ducts, automation and pressure control systems. A significant part of the equipment is produced at our own plant in Temirtau (2 workshops with an area of ​​more than 1,000 m², CNC machine park) – this directly affects delivery times and quality control.
• Installation– using our own installation teams. The deadlines are determined at the stage of approval of the technical specifications and are fixed in the contract.
• Commissioning and maintenance— system testing, microclimate control, transfer of as-built documentation. Conditions for subsequent service are negotiated individually.

Reliability of the company and confirmation of experience in ventilation of clean rooms

Choosing a cleanroom ventilation contractor is a decision with long-term consequences. An error in design or installation is discovered not upon delivery of the facility, but during operation: through failure of classification tests, an increase in particle concentration, or equipment failure at a critical moment. That is why clients of ABL Engineering Group evaluate the company not by presentation, but by specific indicators – in-house production, a confirmed portfolio and team qualifications.

Own production of equipment – quality control without intermediaries

ABL Engineering Group has its own equipment production in Temirtau: two production workshops with a total area of over 1000 m², a CNC machine park. This is not an assembly site – it is a full-fledged engineering production facility where air ducts, housing elements and non-standard components for a specific object are manufactured.

• Quality control at every stage— from metal cutting to final assembly, without dependence on third-party suppliers.
• Exact compliance with project documentation— products are manufactured according to the own drawings of the PTO engineers, which eliminates any discrepancies between the design and installation.
• Reduced delivery times— production capacities allow us to maintain schedules even at large industrial facilities.

Head of Production and SupplyKorzhuk Alexey Alexandrovich personally monitors compliance of manufactured products with GOST and ISO requirements in force for cleanroom ventilation systems.

Experience and portfolio: 40+ objects since 2009

Over the years, ABL Engineering Group specialists have implemented more than 40+ projects – pharmaceutical production lines, microelectronic areas, laboratory buildings, operating units and industrial clean zones. The portfolio covers objects of any scale – from small premises to large production complexes.

Among the company’s clients areArcelorMittal, large industrial plants, shopping centers and office centers. Each implemented object is recorded in technical documentation indicating the cleanliness class, equipment used and test results.

Experience in 40+ sites means more than just accumulated man-hours. These are systematized engineering solutions, proven air distribution control schemes, proven algorithms for calculating air exchange rates and pressure in areas with different cleanliness classes.

Team of specialists: engineers, management, installation teams

Project implementation is ensured by our own installation teams and full-time engineers with specialized qualifications. The team structure is built so that each stage – from technical specifications to commissioning – is led by a responsible specialist.

Technical Department engineers develop design documentation in accordance with the requirements of ISO 14644 and related standards. Installation teams undergo internal certification – work at sites with high requirements for air purity does not allow casual workers.

Compliance with GOST and ISO standards is not a declaration, but a working standard

All cleanroom ventilation systems implemented by ABL Engineering Group are designed and installed taking into account current standards: ISO 14644, SN RK 4.02-105-2014, industry sanitary standards. Compliance is confirmed not only at the stage of commissioning of the facility, but also during operational tests – monitoring particle concentrations, checking pressure, measuring air flow speed.

• Project documentation is drawn up in accordance with the requirements of technical supervision.
• The HEPA and ULPA filters used are certified and comply with the declared efficiency class.
• Based on the installation results, the client receives a complete set of as-built documentation.

ABL Engineering Group works with industrial facilities of any size in the B2B segment. Specialization in production and technological facilities is not a limitation, but a conscious position: it is here that the requirements for ventilation are most critical, and the cost of error is the highest. The company operates in all key regions, including Astana, Shymkent and Aktobe, providing a uniform quality standard regardless of the remoteness of the facility.

Cleanroom Ventilation Frequently Asked Questions

Below are answers to the questions most often asked by technicians, chief engineers and project managers when choosing a cleanroom ventilation contractor. If your question is not included in the list, contact ABL Engineering Group engineers directly.

What regulations and standards govern the ventilation of clean rooms?

Ventilation of clean rooms is regulated by a set of regulatory documents. The basis isISO 14644(classification and control of air purity), international standardsISO 14644-1…14644-4, as well as sanitary and epidemiological requirements and industry standards – depending on the type of production. The room cleanliness class determines the permissible particle concentrations per cubic meter of air, requirements for the air exchange rate, flow pattern and filtration composition. Technical documentation and standards (GOST, ISO) form the basis of the design assignment even before the start of calculations. Compliance with these standards is a mandatory condition for accepting the object and passing tests.

How are cleanroom ventilation systems designed?

Design begins with a survey of the facility and collection of initial data: cleanliness class, area, technological loads, microclimate requirements. Based on these data, engineers calculate air exchange, select equipment and develop an air distribution scheme – supply and exhaust. Design includes:

• calculation of air exchange rate and air supply volume;
• selection of filters, fans and air ducts;
• development of control and automation schemes;
• creating a comprehensive or local solution – depending on the task;
• choice between unidirectional (laminar) and turbulent air flow;
• integration with heating and pressure control systems.

Engineering solutions are recorded in design documentation, which is agreed upon with the customer before installation begins.

What types of filters are used and how do they differ?

HEPA filters(High Efficiency Particulate Air) trap at least 99.97% of particles with a size of 0.3 microns – used in rooms of ISO classes 5–8.ULPA filters(Ultra Low Penetration Air) provide efficiency up to 99.9995% with particle sizes from 0.12 microns – used in the most critical areas of ISO classes 3-4. The choice between HEPA and ULPA is determined by the purity class, nature of production and particle concentration requirements. Both types are installed in the final stages of air purification and require regular replacement according to maintenance regulations.

What are the timing and stages of installation of ventilation systems?

Installation is divided into successive stages:

1. Preparatory stage— supply of equipment, marking of routes, preparation of fastening structures.
2. Installation of air ducts and equipment— laying pipelines, installing fans, filter units, diffusers.
3. Connecting control systems— installation of automatic control of pressure, temperature, humidity.
4. Commissioning work— balancing of flows, checking parameters, testing for compliance with standards.
5. Delivery of the object— transfer of technical documentation, staff training.

The deadlines are determined individually – depending on the volume of work, the cleanliness class and readiness of the object. Specify the parameters of your facility, and ABL Engineering Group engineers will create a realistic schedule.

Is it possible to order maintenance and repair of ventilation after installation?

Yes. ABL Engineering Group performsservice installed clean room ventilation systems: scheduled replacement of HEPA and ULPA filters, checking the tightness of air ducts, monitoring microclimate parameters, calibrating pressure and humidity sensors.Repair carried out both within the framework of the operating contract and on one-time requests. Timely maintenance is a prerequisite for maintaining cleanliness and compliance throughout the entire life cycle of the system.

What guarantees and quality assurances does the company provide?

ABL Engineering Group – work since 2009 in the industrial engineering market, more than 40+ specialized facilities, own installation teams. Own production of equipment in Temirtau (CNC machine park, two workshops with an area of ​​over 1000 m²) ensures quality control at every stage – from manufacturing to installation. Among the clients –ArcelorMittal and other large industrial enterprises. Guarantees and service conditions are fixed in the contract. Confirmation of experience and quality of work – completed projects that can be requested from the manager.

How is air quality controlled and microclimate maintained?

Air quality control in clean rooms is carried out continuously: sensors record particle concentrations, temperature, humidity and pressure in real time. The automatic control system maintains the specified microclimate parameters and signals deviations. Instrumental tests are periodically carried out – measuring particle concentrations, checking the integrity of HEPA/ULPA filters using the DOP/PAO method. The results are recorded in the operation log and serve as the basis for process safety.

In which regions of Kazakhstan does ABL Engineering Group operate?

The company carries out design and installation of ventilation systems throughout Kazakhstan. Main regions of presence:Almaty, Astana, Temirtau, Shymkent, Aktobe and adjacent industrial areas. We work exclusively with industrial facilities of any scale – factories, production buildings, warehouses, laboratory complexes. Departure of specialists and logistics of equipment are organized within the framework of the contract.

How to order a consultation and calculation of the ventilation system?

To get advice and an individual calculation, just contact ABL Engineering Group in any convenient way – by phone or through the form on the website. To prepare a commercial proposal you will need: room cleanliness class, area and height of zones, technological requirements, availability of current documentation. The choice of the optimal solution – supply, exhaust or complex – is carried out by engineers based on the technical specifications. You can order a consultation at any stage: from pre-design work to replacement of the existing system.

What risks are associated with improper ventilation of cleanrooms?

Errors in the design or installation of ventilation create a direct danger to production:

• Risk of contamination— exceeding the permissible particle concentrations leads to product defects and line shutdown;
• Risk of microbiological contamination— critical in pharmaceuticals, food production, medicine;
• Non-compliance with regulatory requirements— entails fines, orders and revocation of permits;
• Reduced cleaning efficiency— incorrect selection of HEPA/ULPA filters or flow diagrams nullifies investment in equipment;
• Danger to personnel— when working with hazardous or controlled substances, impaired air exchange creates a direct threat to the health of employees.

Removing these risks begins with correct design and compliance with standards at every stage – from calculation to operation.