Plascore

Pharma
Cleanroom Wall and Ceiling Systems
TM

MODULAR CLEANROOMS
Plascore Pharma Cleanroom System TM

Superior Quality, Unmatched Flexibility

The Plascore PharmaTM series of cleanroom wall and ceiling Features Summary:
systems is designed for the most stringent medical
research and aseptic process applications. Plascore • Versatile system configurations
Pharma is the modular cleanroom of choice in biomed, life • Built to drawing layout; minimal alterations required
science, biotech, medical device, nutraceutical and
pharmaceutical processing. • Flush ceiling system with wide hanger spacing
• Studless, utility and liner wall options
Plascore Pharma modular wall and ceiling systems offer
significant financial and performance advantages over • Aluminum honeycomb panel core for greater stiffness
traditional clean facility solutions. and fire resistance
• Progressive or nonprogressive panel joints
A Complete System
• Multiple door and hardware options
One of the greatest advantages of the Plascore Pharma
design is its floating flush ceiling with 5' x 10' x 2" (1.5m x • uPVC surfaces, coves and chemically
3m x 51mm) ceiling panels and 5' x 10' (1.5m x 3m) hanger cold-welded seams
spacing, allowing the installation of 4' (1.2m) fixtures, • Stainless steel surface options for panels and doors
oriented in either direction, without changing the ceiling
panel orientation. Three modular wall types — studless • Virtually flush seams for more effective sanitation
walls, hollow utility walls and liner panels — provide the wash-down and fumigation
same flexibility, fine-line seams and finishes as the ceiling • Backed by world-class service
system. Several types of flush doors and windows, as well
as access openings, can be integrated. Plascore Pharma • UL and FM approved
arrives at a prepared job site with all components clean
packaged and ready for fast installation.
Walkable Ceiling System

Walkable ceilings allow easy access to mechanical

systems without disrupting the cleanroom envelope.

The Plascore Pharma ceiling system is a platform of adjoining Like Plascore Pharma wall panels, ceiling panels consist of
5' x 10' x 2" (1.5m x 3m) panels, suspended by turnbuckle/hanger rolled-edge top and bottom steel or aluminum skins bonded to an
assemblies bolted to the corners of four adjoining panels. Cutouts aluminum honeycomb core for a total thickness of 2" (51mm). An
for light fixtures and filters can be placed anywhere, oriented aluminum perimeter frame is bonded between the skins to provide
in either direction, without having to change the ceiling panel additional support, as well as a mounting area for additional hang-
orientation. The ceiling is capable of supporting a wide variety of ers. Ceiling panel edges are tightly engaged to adjoining panels
mechanical systems, accommodating lighting, sprinklers, HEPA with a fixed metal spline.
filters, utilities and small equipment. Interior wall panels are
attached to the bottom surface of the ceiling panels. Since the Openings for equipment (lights, filters, etc.) can be located
bottom surface is flush, free from protrusions, wall/ceiling covings anywhere within the ceiling layout. Cutouts can be cut in the
can be run at any location without concern about grid layouts. factory, or field cut by the installer. Prefabricated, powder coated
metal inserts are available to support HEPA filters and lighting
• No T-grid to support ceiling panels required fixtures in the prepared cutouts.
• 5' (1.5m) wide panel width allows both length and width
orientation of light and filter housings

• 20% reduction in the number of seams

• Large hanger spacing provides generous space for ducting

and maintenance access

• Additional hangers in heavily loaded areas or areas with

excessive equipment penetrations can be added in the field

• Ceiling expansion in any direction is readily accommodated

• Fully walkable by maintenance personnel; entire top surface

is free of trip hazards

• Pharma ceiling systems are offered in both progressive and

nonprogressive panel configurations
Liner, Studless and
Utility Wall Systems

I D A

B
B
M
G

K C

Plascore Pharma wall systems are offered in three designs Studless Wall System
to address typical site and functional requirements:
Studless walls are 2" (51mm) thick and typically serve as
Liner Wall System perimeter, interior and air return walls with requirements
for utility raceways and conduits. Studless wall panels are
Liner wall panels are 0.5" (13mm) thick and are attached to typically installed below the ceiling system.
existing facility walls, or metal stud wall framing, to give
them the same finish and appearance as adjoining new Plascore Pharma studless wall panels consist of rolled-edge
construction. top and bottom steel or aluminum skins bonded to an
aluminum honeycomb core for a total thickness of 2" (51mm).
Plascore Pharma liner wall panels have rolled-edge top An aluminum perimeter frame is bonded between the skins
and bottom steel or aluminum skins bonded to an alumi- to provide additional support, and provide UL approved
num honeycomb core for a total thickness of 0.5" (13mm). raceways for items such as light switches and electrical
Panels snap into clips mounted to the wall system. Panel outlets. Progressive studless wall panel edges are tightly
dimensions are limited to 4' (1.2m) in width and 16' (4.85m) in engaged to adjoining panels with a fixed plastic spline.
length. Wall heights can be as high as desired by stacking
multiple panels. Studless wall panels are typically interior non load-bearing
partitions, 4' (1.2m) wide and are installed between the floor
and ceiling. Although studless wall panels are available up to
16' (4.85m) in length, they can be stacked with intermediate
support from adjoining walls or ceilings.
 A B C

Ceiling Hanger Assembly Coved Corner Adjustable Floortrack

E H

D E F
M

Wall/Ceiling/Cove Framed Wall Panel Raceway

Connection
L J
G H I

Utility Wall System

Liner Wall Ceiling Perimeter Ceiling Perimeter
Utility walls are between 4" and 6" (102mm and 152mm) thick, (Studless) (Liner)
with a 2.5" to 4.5" (63.5mm to 114mm) hollow cavity for verti-
cal and horizontal utility runs. J K

This superior load bearing system is ideal for taller rooms or

walls with extensive utility provisions. Available in virtually
any configuration, the modular framed design easily adapts
to windows, pass thrus and doors. Plascore Pharma utility
walls consist of internal vertical and horizontal structural
framing to which panels are attached on either one or both Raised Air Return Wall Floor at Liner
sides. Utility walls in room interiors will be clad on both
sides. Perimeter utility walls may only be clad on the room
interior side. Panel orientation may be vertical or horizontal L M
to match the intended utility access scheme. Panel dimen-
sions are available up to 4' (1.2m) in width and 16' (4.85m) in
length. Utility walls can be designed to be load-bearing with
wall heights as high as desired, by adjusting the structural
framing and stacking multiple panels.

Panels have rolled-edge top and bottom steel or aluminum

skins bonded to an aluminum honeycomb core for a total Floor at Framed Wall Wall Start/T-Intersection
thickness of .5" (12.5mm). Panels snap into clips mounted on
the framing and are nonprogressive, which is necessary for
ready access to utility connections.
Connecting Floor,
Wall and Ceiling

Built-to-print, Plascore Pharma is designed for all cleanroom

classifications in life science research and production.

Studless Wall Adjustable Floor Track Superior Panel Finishes: uPVC,

The adjustable studless wall floor track consists of a Stainless Steel
two-part aluminum extrusion assembly. The lower part is Plascore Pharma wall and ceiling panels are available with
attached to the floor and accepts the upper part, which is standard snow white uPVC film or brushed stainless steel.
raised and leveled to the desired height. The adjustment
range is 3.5"-5.5" (89mm-140mm). The floor track width facili- Plascore Pharma surfaces perform well against typical
tates a floor cove installation flush with the wall panel, with cleaning solutions and sanitizing washes. Tightly abutting
either vinyl or trowelled floors. uPVC panel joints are chemically cold-welded with a uPVC
paste, creating a contiguous uPVC finish on ceiling and wall
Studless Wall Head Track surfaces. Alternately, stainless steel panel joints are spaced
3/16" (4.76mm) and filled with a silicone caulk. Coved uPVC
The studless wall head track consists of a U-shaped track, corners eliminate entrapment and are more effective in
which is attached to the underside of the ceiling panel wash down, sanitation and fumigation.
system or customer’s existing ceiling. Sliding the top panel
edge up into the head track and dropping it down onto the Repairs
floor track secures the panel in position.
Plascore Pharma offers multiple options to repair
Radius Coves panel damage.

All wall systems are supplied with a 2" (50mm) radius

coving for all ceiling/wall and wall/wall intersections,
assuring a virtually seamless transition. Plascore offers
an integrated injected molded inside and outside cove for
seamless transitions. It’s one more reason Plascore Pharma
helps you meet cGMP standards for pharmaceutical and
biomedical environments.

Load bearing framed walls have Non-progresive panels feature rotating

ample room for utilities. splines for easy room modifications.
Cleanroom Doors
To Suit Your Needs

Plascore Pharma offers two lines of single and double cleanroom

door types designed specifically for pharmaceutical environments.

Aluminum Profile Doors

Crafted in custom aluminum extrusions with double perimeter
seals and optional door bottom drop seal, this Plascore Pharma
door design features a flush jamb and leaf assembly. Available
with upper and optional lower flush glazing and finished with an
epoxy powder coat for maximum durability and chemical resis-
tance, this door style is the most economical solution for less strin-
gent classification areas. Installation into any of Plascore Pharma
wall systems, with at least one side of the door frame and door
leaf being flush with the adjoining wall surfaces, is readily accom-
plished utilizing one of Plascore’s proprietary fastening methods.

Stainless Steel/Powder Coated Metal Doors If you can see it, you can clean it: Plascore Pharma
doors and windows feature easily cleaned hardware.
Door frames and leafs are clad in stainless sheet metal; for the
most damage- and chemical-resistant performance. Door faces
are laminated to a honeycomb core for structural stiffness, provid-
ing the most monolithic design without seams and ledges, flush
with at least one surface of adjoining walls. Windows can be sized
up to 50% of the door surface, flush with both leaf surfaces. This
leaf design is well suited to allow air passage around its perimeter.
This style is also available with a powder coated aluminum skin.

Door Hardware
Plascore Pharma doors can be delivered with most standard
mortised or surface mounted hardware to meet customer require-
ments. Surface mounted hardware is preferred for easy access,
adjustment and cleaning. Cleanroom door hardware can be
provided to meet your specific needs and functions:

• Stainless steel push/pull bars

• Mortised door locksets and strikes, with door handles or

magnetic interlock
• Surface mounted door closers
• Surface mounted electric door operators
• Internal double door extension bolts

Flush Double Glazed Cleanroom Windows

Plascore Pharma window units for doors and studless walls
consist of two panes of 1/4" (6.4mm) tempered glass, bonded
and sealed to an aluminum frame filled with desiccant to reduce
moisture. Windows have the same thickness as the door/wall,
providing a flush installation. Window units are replaceable in
nonprogressive systems, can be adjusted with leveling bolts and
are sealed with a silicone caulk. Windows for utility and liner walls
are typically single pane on an aluminum frame, installed flush
with a silicone caulk seam.
 Competencies
Plascore, Inc. is ISO-9001 registered, and employs Lean Manufacturing
principles throughout design, manufacturing and administration, to
reduce lead time while assuring optimum quality and on-time delivery.
In addition to our proprietary honeycomb manufacturing process, our
value-added capabilities include adhesive development, CNC machining,
powder coating, welding, thermoset and thermoplastic laminating and
assembly. This extensive capability allows us to maintain rigid quality
standards on all cleanroom components, control project scheduling
and deliver cleanroom systems in the manner best suited to the client’s
specific needs.

Design Engineering/Installation Support

Plascore design engineers and sales service staff work closely with
architects, engineers and contractors to ensure Plascore Pharma
Corporate Headquarters
cleanrooms are installed to your complete satisfaction. Our expertise
in cleanroom design and manufacturing, together with our commitment Plascore Incorporated
615 N. Fairview St.
to customer support, is critical to successful installation throughout Zeeland, MI 49464-0170
the world. USA
Phone (616) 772-1220
Toll Free (800) 630-9257
Fax (616) 772-1289
Web www.plascore.com
Email [email protected]

Europe
Plascore GmbH&CoKG
Feldborn 6
D-55444 Waldlaubersheim
Germany
Phone +49(0) 6707-9143 0
Fax +49(0) 6707-9143 40
Web www.plascore.de
Email [email protected]

Plascore, Inc., employs a quality management system that is Nadcap, AS9100, ISO 9001 and ISO 14001 certified.
IMPORTANT NOTICE: The information contained in these materials regarding Plascore’s products, processes, or equipment, is
intended to be up to date, accurate, and complete. However, Plascore cannot warrant that this is always the case. Accordingly,
it is a purchaser’s or user’s responsibility to perform sufficient testing and evaluation to determine the suitability of Plascore’s
products for a particular purpose. Information in these materials and product specifications does not constitute an offer to sell.
Your submission of an order to Plascore constitutes an offer to purchase which, if accepted by Plascore, shall be subject to
Plascore’s terms and conditions of sale. PLASCORE MAKES NO WARRANTIES OF ANY KIND REGARDING THESE MATERIALS
OR INFORMATION, EITHER EXPRESS OR IMPLIED, INCLUDING WITHOUT LIMITATION THE IMPLIED WARRANTIES OF
MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE. Plascore owns and shall retain all worldwide rights in its
intellectual property, and any other trademarks used in these materials are the property of their respective owners. The
information in these materials shall not be construed as an inducement, permission, or recommendation to infringe any patent
or other intellectual property rights of any third parties. © 2018 Plascore, Inc. All Rights Reserved. v04.02.18 MODULAR CLEANROOMS