Semi-Flush ISO 7 Cleanroom

Medical Device Supplier

Background:

CREST were invited to undertake a new ISO 7 cleanroom contract for a medical device developer and manufacturer in Leeds, where cleanroom assembly forms a part of their ISO 13485 operational guidelines.

Process:

The project included a semi-flush cleanroom to meet the client’s ISO 7 standards, where the design encompassed an air lock changing area adhering to an ISO 8 specification and interlocking doors as per the operational workflow of the facility.

Working closely with their nominated contractor, our team put together initial budget costs, which were then confirmed with a full site survey. This visit was crucial as it allowed CREST’s contracts manager to assess the room layout, spatial restrictions and key access points for the cleanroom build.

Project Delivery:

As part of the build, the team were also able to successfully integrate a bespoke architectural design element, so that the envelope concealed the HVAC equipment located on the ceiling, an aesthetically-pleasing addition to the finish of the cleanroom.

Based on a busy industrial estate, an out-of-hours materials delivery schedule was put in place to manage loads coming into the area and ensure minimal disruption to neighbouring businesses and ultimately, the full scheme of works.

CREST demonstrated flexibility and expert product knowledge

Paul Towse, CREST Project Manager

Location	Leeds
Building Use	Medical Device Manufacturing
Panel Core	QuadCore
Panel Supplier	Kingspan
Panel Thickness	80mm, 100mm
Panel Requirements	131m²
Services	Dedicated Medical Industry Expertise
	On-Site Flexibility
	Cleanroom Envelope Design & Build
	Flexible Build Programmes to Suit

Battery Manufacturer Cleanroom

Lithium Battery Research

Background:

As a result of our expertise and bespoke cleanroom envelope packages, Stancold were awarded a new-build contract with a battery research organisation that specialises in reusing and recycling tin mining materials to create lithium batteries.

Process:

The client requested the new-build cleanroom as part of a pilot phase for a large-scale facility in the long-term.

Throughout the contract, the team collaborated closely with the manufacturing equipment contractor, who would later install the new machinery.

Included in the scope was the design and installation of double personnel doors for ease of access and a vision panel to enhance visibility within the facility.

Project Delivery:

The team’s flexibility and proactive nature allowed them to build the initial walls during the first site visit, leaving a pre-designed opening to allow for the manufacturing equipment to be installed.

Due to the nature of the client’s work, a phased installation was required. The second phase began once the new equipment had been installed, resulting in the team returning to seal the room.

As per the client’s request, the team installed treadplate wall protection across the cleanroom perimeter in order to minimise the risk of potential damages.

The teams’ flexibility in this project left the client satisfied with the results.

Mark Kendrick, Business Development Director

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University Coldstore Facility

Veterinary Anatomical Research

Background:

As part of a coldstore scope for a university veterinary facility that stores equine cadavers, an existing M&E contractor client of CREST approached the team directly to install a dual-compartment chiller and freezer.

Process:

The initial site survey demanded a high degree of flexibility from the team in order to coordinate closely with the University to avoid disrupting scheduled research and classes.

The team also ensured that particular care was taken to safeguard delicate learning materials by ensuring they would be carefully relocated and secured before the team entered the site.

As part of the project scope, the chiller and freezer were each fitted with manual sliding doors for ease of access.

Project Delivery:

Upon arrival on site, the team demonstrated exceptional adaptability by seamlessly integrating into a live working environment without disrupting ongoing academic activities as a result of working within a secured construction area.

The team’s commitment, along with an extensive and specialised skill set, allowed for the installation process to go smoothly and be completed to a high standard.

Our team worked incredibly hard and overcame the challenges of working in a live environment.

Bob Stevenson, Senior Design and Coordination Manager

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N+1 Air Freight Storage Facilities

Air Freight Services

Background:

Following the success of a prior project, CREST were contacted directly to help a pre-existing client design and build a coldstore, freezer, and ambient room for their second warehouse following a relocation.

Process:

The client required a fast turnaround, prompting CREST’s team to conduct a comprehensive site survey within just four days of the initial enquiry.

The scope of the project included the design of a bespoke reinforced freezer floor. Due to the nature of our client’s onsite operations, the traditional concrete flooring wouldn’t cope with the pressure from the excessive weight of the cargo pallets.

Our team’s strong communication and commitment to meeting client needs enabled us to deliver three high-quality designs, giving the client clear options to match their requirements.

Project Delivery:

Despite the tight schedule, the team were fully prepared to begin installation on-site within six weeks of the initial enquiry.

Due to the nature of the client’s work, the challenge of working in a live everchanging environment was presented. However, with the team’s extensive installation experience, the planning and delivery service ran smoothly.

Along with the bespoke freezer flooring, as part of the project scope we provided our N+1 refrigeration package that conducts constant temperature-mapping.

Our team worked incredibly hard in a live working environment.

Bob Stevenson, Senior Design Manager

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Cleanroom Reconfiguration

Specialist Coatings

Background:

After a prior successful installation, CREST were approached directly to reconfigure 25% of the previous cleanroom installation to allow for larger equipment to be installed.

Process:

Due to the size of the new larger machinery, as part of the scope, the team were required to design and build a new bulkhead in accordance with the existing facility plan.

Not only did the walls and ceilings of the selected area need to be redesigned, but the fire escape system and refrigeration airflow systems also needed to be updated to accommodate the new area layout.

Project Delivery:

Upon arrival, the team faced a strict two-week shutdown to accommodate our work. The team’s ability to work flexibly to the client’s needs further allowed for a planned phased construction. Once the machinery was in place, the team returned to the site to complete the build.

The team also reconfigured the site’s airflow system to ensure the correct temperature and air control was in place.

The team ensured the safety of the pre-existing manufacturing equipment by maintaining a controlled environment by sectioning them off, creating a clean and secure workspace.

The team have been incredibly flexible in their working conditions, we couldn’t be more proud of them.

Steve Gunning, CREST Contract Manager

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ADC Manufacturing Facility Fit-Out

Principal Contractor

Background:

Based on over 7 years of successful history in delivering high-value critical environment projects together, a principal contractor selected CREST for the fit-out scope of their turnkey contract for a global pharma company’s UK ADC manufacturing facility in Scotland.

Process:

Thanks to CREST’s expertise in such projects, we worked with the client and third parties since the early stages, attending their weekly design meetings to consult on the envelope specification and provide a detailed drawings within their Revit model.

CREST’s scope of works included the cleanroom envelope fit-out of two levels of a three-storey building, with multiple GMP Grade C & D cleanrooms and a large pharmaceutical cold store. Systems specified included Puracore and Kingspan Versatile.

Project delivery:

Due to the complex nature of the project combined with large area covered by its scope, totalling 1750m², CREST appointed a full-time site manager.

With their proactive approach and vast experience running critical environment fit-outs, the team was able to predict challenges, act and implement changes instantly, allowing the client to hand over the building in a timely manner.

Outstanding work from our teams to ensure the variety of systems and details blended together seamlessly.

Bob Stevenson, CREST

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FM Approved Cleanroom Upgrade

Electronic Components Manufacturer

Background:

Our client, a global manufacturer of electronic components for the automotive sector, contacted CREST with a need to upgrade their existing cleanroom facility on site in Bedford.

They sought after an architectural envelope contractor that could supply and install an FM approved cleanroom system in order to comply with their latest insurance conditions.

Process:

Following a site visit to understand the scope of the project in more detail, CREST proposed to undertake the removal of existing cleanroom walls followed by their replacement with the FM Approved Puracore system, including all doors and vision panels.

Given our client’s operational commitments, a 10-day shutdown of the main cleanroom was agreed, but most of the works on site had to be completed while it was still operational.

Project Delivery:

Working within a live cleanroom environment required a stringent construction schedule and daily health & safety briefings to manage personnel moving in and around the works area.

This also meant that some areas of the existing cleanroom envelope couldn’t be assessed while the original site surveys were carried out, so CREST’s site and in-house design teams worked in real time to identify issues and update drawings.

The flexibility of Puracore’s cleanroom system combined with CREST’s experienced workforce allowed for on-site adaptations easily, which saw the build handed over within 12 weeks.

A real pleasure to assist our client with this cleanroom upgrade.

Lee Duffield, CREST Construction Director

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Development Lab Extension

Equans

Background:

A turnkey contractor enlisted Stancold to deliver the cleanroom envelope for a Deeside pharma extension, where the existing Kingspan system would be complemented by the specified MIDDAS non- progressive panels and associated framework.

Fortunately, Stancold’s team has extensive experience delivering this type of cleanroom envelope project.

Process:

The team collaborated with MIDDAS and the contractor to design the envelope, reworking the Kingspan layout to form a lobby and incorporating fire rated MIDDAS panels.

MIDDAS offers their panel systems with a mineral fibre core to satisfy fire-rated requirements.

Project Delivery:

Over four weeks on site, Stancold installed the cleanroom layout, combining the existing Kingspan system with a bespoke MIDDAS framework for the extension, including a gowning room and lobby, and complete with the specified MIDDAS doors and vision panels.

Stancold also managed the installation of a Kingspan vision panel and infill panel in the existing space of the facility.

Our team values any opportunity to further our experience with non-progressive cleanroom panel systems like MIDDAS.

Our team reliably delivers cleanroom envelope builds using either a progressive panel system or a non‑progressive system such as MIDDAS.

Mark Kendrick, Business Development Director

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non-progressive cleanroom; development lab extension

Divisional Wall for a Medical Equipment Manufacturer

Intersurgical

Background

Intersurgical, a global manufacturer of respiratory care devices, reached out to Stancold to commission a divisional wall separating their production and storage areas.

Their facility manager recommended composite panels to their leadership team, which they had no previous experience in, therefore creating an opportunity for Stancold to offer our expertise and years of technical experience.

Process

Our team conducted a thorough site visit and proposed a non-fire-rated solution based on Kingspan Quadcore panels. We also recommended a set of rapid-rise doors to further limit dust from spreading to the critical parts of the warehouse.

The main project challenges included:

Introducing composite panel construction to a leadership team unfamiliar with the specification
Ensuring partial operational continuity throughout the build in a sensitive manufacturing environment

Project Delivery

The build was completed in just 10 days. Using Kingspan Quadcore panels, Stancold successfully divided the production and storage areas while the facility remained partially operational throughout.

Impressed by Stancold’s flexibility and the quality of the completed works, Intersurgical’s leadership team made the decision to adopt composite panel solutions for future projects, serving as a testament to our technical expertise.

We are extremely impressed with Stancold. The focus the team gave the project and their adaptability were brilliant. They will be my company of choice in the future.

Richard Howse, Facilities Manager

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Medical Research Cold Storage

Cancer Treatment Research

Background:

CREST were invited by the project’s main contractor to tender for the turnkey cold room package that formed part of a new cancer research and treatment centre in central Manchester. Spanning ten storeys, the vast building required cold storage facilities for drugs and biocultures across four levels.

Process:

The package required the supply and installation of three dual compartment stores and four separate chillers and freezers within the building, which included the envelope build, refrigeration, flooring and lighting. Freezer temperatures needed to be at -20°C and chiller temperatures at +4°C.

CREST’s team were pivotal in providing guidance and support on the room specifications to both the contractor and the architect throughout the contract negotiation process.

Project Delivery:

Due to the size of the building and the different working locations for our team, loading procedures to get materials and plant to the necessary levels were complex. A small goods lift was available to be booked for use by contractors on site, so required thorough planning from our team to ensure our works schedule was not impacted by loading delays.

Used to the challenges of large-scale contracts, the team demonstrated flexibility as the construction programme frequently changed, while working systematically alongside other trades on site to co-ordinate installation activities.

It was a privilege to be involved in this transformational research facility

Mark Kendrick, CREST Business Development Director

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N+1 Laboratory Cold Store

Cravencroft

Background:

CREST were approached by South-East engineering contractor, Cravencroft, for the turnkey supply and installation of a cold store, as part of wider refurbishment works for a biotechnology services provider.

Process:

Located in the sample storage area of a laboratory, the +4°C cold store specified N+1 redundancy capabilities as part of its operation, so required an experienced contractor to confidently undertake all elements of this package.

Satisfied with the level of detail provided from CREST during tender stage, Cravencroft appointed the team as the turnkey cold storage contractor for this project.

Project Delivery:

CREST’s dedicated installation team successfully supplied and installed a cold store with an N+1 refrigeration system that met +4°C temperature specification. This included an auto changeover function to initiate the backup system if necessary.

The room itself was to be housed within a number of other traditional build rooms, generating a tight co-ordination programme for CREST’s first fix refrigeration works. Once complete, other trades were scheduled to carry out their responsibilities before our installation team could continue their build package.

This was another successful pharmaceutical cold store contract for CREST, utilising key technical expertise for the safe storage of high-value sample materials.

CREST demonstrated exemplary co-ordination all throughout the project.

Lee Duffield, CREST Construction Director

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Cleanroom Suite Fit-Out

Biopharmaceutical Manufacturer

Background:

Stancold were engaged for the architectural cleanroom envelope package on a biopharmaceuticals manufacturing facility fit-out in Portsmouth.

Working alongside the principal contractor, Stancold combined cleanroom envelope expertise with passive fire protection capabilities to meet an ISO 7 specification across four mould shop cleanrooms and a mould tool store, alongside a 60-minute fire rating to a 13m-high compartment wall.

Process:

As a large-scale project utilising nearly 10,000m² of composite panelling, our team worked closely with the customer’s design and project team from the early stages to accommodate a changing end user specification.

Based on this, Stancold recommended the Kingspan Versatile cleanroom system for all controlled areas, with Euroclad Firemaster integrated for the fire-rated elements – combining both systems within a single build to meet the full specification without compromising programme or budget.

Project Delivery:

The build incorporated tight timescales and close coordination with multiple trades, ensuring steel frames and HVAC were in place ahead of wall and ceiling installation. The design also incorporated supporting airlocks, changing areas and clean-not-classified corridors.

The team worked in strong collaboration with the customer to synchronise works around a gantry crane system running the length of the cleanrooms, with multiple installation teams working concurrently across different areas of the facility to maintain programme.

This was a technically demanding project from both a specification and programme standpoint, successfully overcome through Stancold’s collaborative approach and expert delivery.

This project asked us to bring cleanroom and fire protection expertise together in a single envelope solution, and that's exactly one of the applications where Stancold's strengths lie.

Mark Kendrick, Business Development Director

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Turnkey Pharmaceutical Cold Stores

Overbury

Background:

CREST were approached by leading fit-out company, Overbury, as a specialist pharma cold storage contractor for one of the world’s leading biopharmaceutical innovators.

A pharmaceutical cold room was required on each floor of the end user’s two-storey research & development site in Stevenage, and came as part of wider ongoing refurbishment and modernisation works.

Process:

CREST’s expertise in turnkey cold store construction for high-value pharmaceutical products confirmed that we were able to provide vital N+1 redundancy solutions and select a sustainable refrigerant option in line with the project specification.

Our team worked closely with Overbury during negotiations to ensure that the specification and build programme were in line with the end user’s requirements.

Project Delivery:

Both turnkey cold room packages were designed and built to maintain an internal temperature requirement of +4°C. The rooms themselves utilised a panel system with FR30 rating, as per the contract’s specification.

Working on the first and second floor of the building meant materials were maneuvered via an internal freight lift and external hoist, a challenge that the team are well-versed in navigating from previous site experience.

Aligning our start on site with a rescheduled programme of works required pro-active coordination to ensure that the project was completed in a timely manner and to the end user’s satisfaction.

A successful turnkey contract for high-value pharma products

Steve Gunning, CREST Contracts Supervisor

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ISO 7 Laboratory

Mildren Construction

Background:

Following Stancold’s work with main contractor, Mildren Construction, for fire-rated and food-safe environments over the years, the group’s dedicated cleanroom entity, CREST, were invited to tender for the architectural cleanroom envelope construction of a temporary cleanroom in Southampton.

Process:

The end user required a temporary cleanroom within their new warehouse space as a stop-gap solution for their future expansion.

The 180m² cleanroom had a requirement to meet ISO 7 standards, so CREST were able to specify a cleanroom envelope system best suited for this type of application.

The team continued to revise their proposal in line with design changes until the final order was agreed.

Project Delivery:

The team utilised Kingspan’s Versatile system for the cleanroom envelope build, which included the integration of double leaf cleanroom doors and semi-flush vision panels to meet an ISO 7 standard.

CREST mobilised quickly to adhere to the proposed programme of works, co-ordinating our construction schedule in line with other trades working on site. Our dedicated team of envelope installers successfully completed the build in less than 2 weeks, leaving Mildren Construction and the end user satisfied with the works.

CREST were a pleasure to work with on this project and the service was seamless from initial pricing through to design and subsequently installation

Richard Holmes, Mildren Construction Director

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Biomedical Holding Freezers

Cell & Gene Therapy Manufacturer

Background:

CREST previously completed the envelope fit-out of six cleanroom suites on this pharmaceutical manufacturing site and thanks to unrivalled knowledge of turnkey cold storage construction within the industry, were subsequently appointed for this requirement too.

Process:

Situated in a modular warehouse on the ground floor of the site, our client required two industrial freezers for additional product storage. The specification required product to enter the room at -20°C and be maintained at this temperature.

CREST undertook the turnkey package, which included refrigeration, lighting, shelving and access ramps.

Project Delivery:

CREST successfully coordinated the room build, commissioning of refrigeration and installation of internal shelving in line with our client’s specification.

The scope also included removable access ramps, person trapped alarms and door release functions, with racking designed around evaporators to optimise airflow.

Utilising knowledge of the different elements required for a turnkey solution like this ensured a seamless programme of works through CREST as the appointed contractor.

CREST has unrivalled expertise in turnkey pharma cold storage.

Steve Gunning, CREST Contracts Supervisor

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GMP Grade C & D Cleanroom Envelope Modules

Principal Contractor

Background:

CREST were pleased to work with an off-site construction specialist to deliver 14 EU GMP Grade C & D cleanroom modules for a new state-of-the-art pharmaceutical innovation facility specialising in medicines and vaccine manufacturing.

Process:

Through a combination of traditional and modular construction practices, CREST were required to fit out the cleanroom modules off-site before they were transported to the facility in Darlington and integrated over two floors. Our expert team developed an architectural envelope specification that not only met the cleanrooms’ GMP conditions, but also took into account the intricacies with the logistics of the project.

Project Delivery:

CREST’s dedicated installers utilised the Puracore cleanroom system, complete with flush doors, flush vision panels and a PET finish that could withstand the use of vapourised hydrogen peroxide (VHP) within its cleaning regime.

Once the modules were in situ, a final visit to the Darlington facility allowed our team to quality-check and cover finer details within the build.

The team worked tirelessly to ensure that the design and material lead-in were co-ordinated to the build programme, achieving a turnaround time of 14 weeks.

CREST showed flexibility through such an intricate project.

Lee Duffield, CREST Contracts Director

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Fire-Rated Cleanrooms

Aerospace Technology Supplier

Background:

Following previous experience with the contractor, CREST were invited to tender with Rydon Construction for the fire-rated cleanroom fit-out of a new purpose-built aerospace centre in Bristol.

Process:

Our team were involved from the early stages of this project to assist with the technical specification that included both passive fire protection and ISO standard cleanrooms.

Negotiations and design meetings were conducted virtually due to COVID-19, before site surveys followed once the green light was given for the project.

Project Delivery:

CREST installed composite walls, ceilings, doors and vision panels to form a number of areas as part of the fit-out. This included production and preparation zones and accompanying airlocks.

The project utilised Eurobond’s Firemaster system with a white food-safe coating throughout, which achieved both a FR30 rating and a cleanroom finish to meet the specification requirements. System doors were also included to ensure no necessary additional secondary steelwork was needed.

Working alongside other contractors within an open warehouse required methodical planning and co-ordination by the team and was managed well to ensure that our build schedule was uncompromised.

You managed issues with delay (by others) well.

Neil Spurway, Rydon Construction

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Fire-rated cleanrooms for aerospace Bristol

FR30 and cleanroom finish across the facility

Chilled & Ambient Pharmaceutical Storage

Pharmaceutical Distribution

Background:

CREST were approached by our client to deliver temperature-controlled pharmaceutical storage within their existing warehouse. Our team were able to offer a turnkey package and assumed responsibility for the panelling, refrigeration, lighting, doors and door protection.

These environments were to be utilised for the storage of temperature-critical pharmaceutical products and aid our client’s compliance for Good Distribution Practice (GDP).

Process:

Understanding the bespoke nature of critical environment builds such as this, the team completed multiple site surveys to gain a better understanding of the site conditions and to confirm minor design changes.

Project Delivery:

Our specialist installation team successfully supplied and installed the pharmaceutical chiller, meeting the 2-8°C temperature specification, with adjoining ambient area (15-25°C), and utilised Kingspan’s QuadCore panel system to do so effectively. Situated underneath a mezzanine floor, the team had to carefully plan the coordination of refrigeration and HVAC equipment to accommodate.

Whilst there was good access to the site, it remained a live environment, so daily coordination meetings were arranged to minimise disruption to day-to-day operations.

However, the team are well-versed in overcoming such intricacies and worked hard to successfully deliver the project according to our client’s programme of works.

A build that demonstrates our pharma expertise.

Lee Duffield, CREST Contracts Director

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Pharmaceutical distribution chiller build

Cleanroom Extension Fit-Out With Firewalls

Pharmaceutical Manufacturer

Background:

Working under on-site project management contractor, the end users’ nominated contractor, who were responsible for developing a full turnkey cleanroom solution, CREST were tasked in undertaking the cleanroom envelope fit-out within this pharmaceutical manufacturer’s new extension.

Process:

The project required an intricate scope of works to best accommodate the end user’s accelerated manufacturing plans and utilisation of redundant space, in and around complex steel structures.

Our team’s consultative nature allowed us to explore a number of panel system combinations with the end user, taking into account the need for fire protection and their budget.

The final package required the integration of three different panel systems to ensure that the specification was successfully achieved.

Project Delivery:

CREST’s responsibilities included the construction of all cleanroom walls, walk-on ceilings, doors, vision panels and 60-minute firewalls, amounting to nearly 8000m² of works.

The team combined Puracore’s Aluminium Honeycomb, Kingspan Versatile and Eurobond Firemaster panel systems to complete the works, utilising each system’s advantages to match the overall complexity. A key strength within our offering includes the ability to accurately colour match all systems, which provided a perfectly white finish throughout this facility.

Two installation teams worked in unison to complete the construction of the cleanrooms and firewalls simultaneously, so the project was successfully finished within the assigned schedule of 15 weeks.

A complex build that exhibits our specialist knowledge.

Lee Duffield, CREST Contracts Director

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Temperature-Controlled Biopharmaceutical Production Facilities

Lifesciences Manufacturer

Background:

A commercial workplace specialist fit-out contractor required CREST to undertake the design and build of four temperature-controlled facilities within a newly built warehouse in Hampshire. The facilities would be used to house the final testing of their production line.

Process:

CREST worked closely with the appointed commercial contractor and our recommended refrigeration partner to find a system that would accommodate the required temperature range of +2°C to +26°C.

Where the facility operates a large robotic crane, CREST also carefully considered different door options and proposed a suitable solution as part of our package.

Project Delivery:

CREST delivered four chilled controlled environments and accompanying doors to facilitate this project’s specification. Kingspan’s QuadCore panel system was the best suited option for this application, thanks to its reliable insulating properties, and space-saving roller-shutter doors integrated within the design to accommodate the warehouse’s crane.

Two areas were built beneath an 8m-high mezzanine floor, so the team created an efficient workaround plan to install ceilings safely, where access was particularly tight. Manoeuvrability of wall panels and use of lifting equipment in this space were also carefully monitored, especially when coupled with other craning machinery within the main warehouse.

CREST successfully completed the works within 3 weeks, demonstrating strong expertise and faultless construction technique for this application.

Our team successfully achieved the intricate specification

Sam Glover, Senior Contracts Manager

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Industrial Battery Manufacturing Centre – Internal Fit-Out

Principal Contractor

Background:

Coventry’s UK Battery Industrialisation Centre (UKBIC) is a new state-of-the-art facility to support the research, development and evolution of high-volume manufacturing of advanced battery technology. For use initially within electric vehicle production before scaling more widely, this Government-funded space will help support the UK’s move to become a low carbon economy.

Due to CREST’s technical expertise and innovative approach, we were engaged by a principal contractor in the early stages to develop and assist the design.

Process:

Due to CREST rich history of over 75 years of temperature-controlled environments and understanding of passive fire construction, we were able to work tirelessly and collaboratively with suppliers and the client’s projects team to ensure a robust ‘right-first-time’ solution to meet the onerous specification:

• ISO 8 cleanroom condition
• -73°C dew point supply & -60°C dew point return
• Temperature 21 +/-2°C
• Ambient air humidity as low as 0.5%
• 60-minute fire-rating
• Static dissipative

Project Delivery:

CREST’s exclusive cleanroom installation team completed the construction of 31 assembly rooms including:

• Anode and cathode mixing facilities
• Anode and cathode calendaring areas
• Material airlocks, personnel airlocks and changing rooms
• Pouch assembly and filling
• Linking corridors

This accommodated two main production lines running parallel throughout the building, complete with ageing ovens for the final stage.

A mix of insulated and fire-rated products were used, along with specialist detailing to ensure that the installation passed the rigorous commissioning and testing procedures, vital for such a sensitive manufacturing process. ‘Free-spanning’ panels in excess of 9m were integrated into the design by CREST, thus eliminating the need for tonnes of secondary steel, whilst still ensuring the fire rating was achieved.

All panel systems and ancillaries were meticulously colour-matched and complete with a 120-micron PVC laminate finish for a seamless integration and maintenance of cleanliness throughout. Openings were carefully created to allow machinery to pass through each area and neighbouring link corridor.

With a build time of 10 months, our team worked tirelessly from project conception to the final handover to develop, supply and install an envelope that would meet the complex specification required for this new generation of high-end and high-volume manufacturing.

Stancold went above and beyond in demonstrating our capabilities

Lee Duffield, Senior Contracts Manager

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Complex specification for industrial battery manufacturing centre fit-out

ISO 8 Cleanroom

Electrical Connectivity Manufacturing

Background:

CREST worked with cleanroom contractor, Monmouth Scientific, in Dundee to successfully construct a new cleanroom for an electrical components manufacturer.

Process:

CREST’s strong expertise in the design and build of the cleanroom envelope were fully utilised throughout this project, where three different panel systems were integrated to create a new ISO 8 cleanroom and glazed office partitioning.

Our team were able to offer valuable advice on each system and discuss how it would work within the finished facility, all confirmed with a site survey to visualise the agreed design and understand site conditions.

Project Delivery:

The project encompasses approximately 523m² of insulated panelling, with the ISO 8 cleanroom constructed using the semi-flush Kingspan Versatile system, of 100mm thickness.

The accompanying office space utilises a Puracore glazed wall system, which includes 50mm Aluminium Honeycomb panels with frosted double-glazed flush windows and a fully glazed door. All ceilings across the two areas employ the Kingspan Versatile system. Mineral Fibre panelling was also installed as part of this project’s specification.

Our installation team’s panel construction expertise was fully exercised throughout, as the build was carried out while the facility remained operational, thus not impacting on the end user’s production capabilities.

Utilising three panel systems demonstrated the team's excellent construction experience.

Lee Duffield, CREST Contracts Director

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Inside the ISO 8 cleanroom for electrical component manufacture

Cleanroom for electrical component manufacture

Sterile Production Areas

Pal International

Background:

Manufacturer of cleaning & PPE products, Pal International, approached CREST in the midst of the COVID-19 pandemic. Due to the Government advice imposed across the UK, they saw their product range in significant demand. To facilitate this sudden increase, they required additional space to house a new production line.

Process:

CREST reacted quickly across every aspect of this project. To ensure the client made effective use of their vacant space, we undertook a consultative approach and value-engineered a design that utilised existing walls.

Where the project needed to be on site within a matter of weeks, our long-standing relationships with manufacturers and suppliers were vital in ensuring a rapid turnaround to begin construction.

Project Delivery:

The project’s final design involved 6 new hygienic areas, all at differing heights, with openings to accommodate product equipment, alongside the installation of personnel doors.

Kingspan’s QuadCore panel system was best suited for this build, due to its high-quality hygienic finish. Ongoing circumstances meant that health & safety was a key consideration while working on site, where the team adhered to strict social distancing measures and precautionary checks as advised by Pal International.

CREST’s ability to mobilise quickly and work efficiently during such unprecedented times ensures that our client’s tight schedule was met and their operations unaffected.

Demonstrating efficiency and safety were key in this project.

Sam Glover, Stancold Contracts Manager

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Hygienic Rooms Built For New Production Lines

ISO 8 & 9 Cleanroom Areas

Aerostructures Manufacturing

Background:

Working with a turnkey cleanroom contractor, our end user required ISO standard 8 and 9 areas as part of a new aerostructures research and development complex within a large hangar in West Scotland.

Process:

A site survey determined all design and construction details for the project, allowing our CAD team to expertly create accurate drawings, gaining approval from the client and preparing the CREST team for the build.

Co-ordination of materials, plant and ancillaries was a key factor of the planning process, given its rural Scottish location and 400-mile distance from CREST’s Head Office.

Solution:

CREST completed the install using Kingspan Versatile QuadCore panels, a composite system designed for semi-flush cleanroom environments such as this.

The team were responsible for all 50mm and 80mm hygienic panelling, spanning over 1500m², and the 100mm walk-on ceiling, to be used for maintenance access. Rapid-rise doors, personnel doors and single-glazed vision panels completed the build.

The team worked really hard to construct within and around the existing steelwork on site, alongside other contractors, to complete the project to our client’s programme of works.

A successful cleanroom build for an exciting project

Lee Duffield, Stancold Project Manager

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GMP Manufacturing Cleanroom Suite

Cell & Gene Therapy Manufacturer

Background:

CREST have built a strong relationship with this project’s successful main contractor thanks to previous experience together and were selected to complete the cleanroom works as part of this expansion project in Stevenage.

Process:

As the project’s design evolved, CREST worked tirelessly to revise quotations to suit, meeting with the contractor to see the site’s existing cleanrooms and expansion area. This was also where our design and projects teams later clarified construction details, panel layouts and programme to ensure a smooth start to the installation.

Where the new suite will undergo tough cleaning regimes when fully operational, it was key that the products used for the build would be able to withstand such levels. CREST were pro-active in submitting all technical information for the end user’s approval.

Solution:

The manufacturing suite utilises the fully flush FM Approved Puracore cleanroom system in order to achieve the desired Grade C & Grade D standard throughout.

Fully flush vision panels with 6mm toughened glass are incorporated within the Aluminium Honeycomb partitioning while all service points are neatly integrated.

Over 100 fully flush single and double personnel doors have been installed, complete with a motion-sensor interlocking network from main corridors to airlock spaces through to cleanrooms, preventing contamination.

A walk-on ceiling with a hidden suspension system allows for maintenance access where required, while bump rails within the clean not classified corridors and material airlocks add protection to outer cleanroom walls.

Our experienced installation team completed this project in 6 months, where our dedicated workmanship and attention-to-detail demonstrated CREST’s unrivalled Puracore expertise, from design through to final handover.

CREST's scope of Puracore cleanroom installation excelled in this project.

Lee Duffield, CREST Contracts Director

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Low Humidity Cleanroom

Battery Technology

Background:

CREST recently travelled to Romsey to install a fully flush cleanroom system for a specialist in solid-state battery production.

Process:

Our extensive knowledge of different cleanroom systems on the market allowed us to suggest what would be best suited to this project and then adapt based on the user’s specific requirements.

Once confirmed, our projects team commenced with site surveys, construction drawings and door schedules in preparation for the start date.

Project Delivery:

CREST utilised the Kingspan Precision cleanroom system; a framed, flush system where panels were made to size, alongside the expert installation of flush vision panels, a full-height glazed wall and flush hinged personnel doors.

Chiller doors were also selected and integrated into the build of the main cleanroom areas, as they demonstrated the most appropriate sealing properties to establish a very low humidity level that is required when working with lithium.

Being able to adequately meet the various requirements of this project, from humidity levels to a fully flush system, was due to the team’s experience and knowledge in working with market-leading materials, therefore creating a bespoke facility that met our client’s needs.

Our superior knowledge of the cleanroom market was valuable

Lee Duffield, Project Manager

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Advanced Research Laboratory

AMRC - University of Sheffield

Background:

Following a glowing reference from a cleanroom project on an alternative site, CREST were recommended for these works with the University of Sheffield for The Advanced Manufacturing Research Centre (AMRC), who were continuing to expand their operations within their powder manufacturing and processing facility.

Process:

Utilising strong industry experience, CREST developed the concept and produced a design proposal for the works, which was then finalised through a site survey with the project management team.

Project Delivery:

Our team were responsible for installing Kingspan QuadCore panels of 80mm thickness and a walk-on ceiling of 100mm to form the laboratory. Alongside this, the integration of hinged personnel doors and vision panels were completed.

CREST also undertook the installation of the accompanying air conditioning and humidity control functions, so that the facility was able to maintain a consistent 20°C. This was crucial for the activities taking place within the lab.

This project was successfully completed in four weeks and CREST left site with a satisfied end user.

Successfully developing the lab's concept and design was due to strong industry experience.

Lee Duffield, CREST Contracts Director

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4,000m² Fill Finish Cleanroom Facility

BES

Background:

After working together previously, respected specialist cleanroom contractor, BES, invited CREST to tender for the installation of 4000m² of cleanroom panels in their latest pharmaceuticals project.

Process:

This project required CREST’s expertise and experience within pharmaceutical cleanrooms to install Aluminium Honeycomb and insulated panels, forming a new Fill Finish facility. The end user, a worldwide manufacturer and supplier of vaccines, were moving this area of operations in-house to their manufacturing site in Liverpool.

Project Delivery:

CREST installed both Kingspan QuadCore and Puracore Aluminium Honeycomb panels to successfully complete the fit-out. Covering two floors of the facility, the cleanrooms were constructed simultaneously by two separate CREST teams, achieving a semi-flush environment within the lower level and a fully flush, high-end pharmaceutical cleanroom on the upper level.

The build also included the integration of flush single hinged, double hinged and personnel doors, as well as double glazed flush vision panels. Three cold storage units were also required as part of our installation package.

CREST’s strong technical ability in installing controlled environments was fully utilised throughout this 20-week project on site.

With a difficult design to follow and a tight programme, it was an excellent install.

Steve Daly, Boulting Environmental Services

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Pharmaceutical Cold Storage

BES

Background:

After working together previously, respected specialist cleanroom contractor, BES, invited CREST to tender for the cold storage works in their latest pharmaceuticals project.

Process:

Alongside the fit-out of a composite cleanroom envelope with panels that measured over 4000m², the large project required CREST’s expertise and experience to integrate three pharmaceutical cold stores, including refrigeration, within the new Fill Finish facility.

The end user, a worldwide manufacturer and supplier of vaccines, required facilities to house their products and materials under controlled temperature conditions.

Project Delivery:

CREST installed Kingspan panels to create the three cold stores and integrated with insulated rapid roller doors, fire escape doors and insulated sliding doors for efficient product and personnel access.

Two cold stores on the ground floor required a ‘controlled not classified’ status while the third, located on the first floor, needed to achieve ISO 8 (Grade D) standard. The units have been constructed to achieve a temperature range of +2°C to +8°C in order to meet the requirements of the product.

Like in many pharmaceutical cleanrooms where the value of the product being stored is so high, all cold stores required 100% backup, so if any equipment fails, the rooms will still remain fully operational.

This project demonstrated CREST’s full capabilities in installing pharmaceutical cold storage, using our extensive technical knowledge to meet the needs of our clients.

With a difficult design to follow, it was an excellent install.

Steve Daly, Boulting Environmental Services

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Fully Flush ISO 8 Cleanroom Suite

Supplement & Probiotic Manufacturer

Background:

CREST have a long-standing relationship with cleanroom specialists, NGS Cleanrooms, who undertook the design and construction of an ISO 8 cleanroom suite for their client, a probiotics manufacturer in Somerset.

Process:

CREST worked closely with NGS Cleanrooms and Puracore, producing detailed design plans for the large bespoke cleanroom build.

Solution:

The project required the installation of 1250m² of FM Approved Puracore Aluminium Honeycomb Cored panels, fully flush vision panels and rapid roller shutter doors to form 28 processing rooms.

CREST also supplied and installed an integrated FR60 firewall, using Kingspan Mineral Fibre Cored 100mm panels. This included the fitting of double ‘hold open’ fire-rated personnel doors and all firestopping to achieve maximum fire integrity. CREST were responsible for the suite’s cold storage facility, constructed using Kingspan QuadCore panels and completed with a white food-safe finish to match the rest of the Grade D cleanroom suite.

There were a number of intricate and complex details to the project, such as the seamless integration of motion-sensor service points for doors and air return columns. CREST’s specialist expertise and strong cleanroom experience enabled the 6-week bespoke project to be completed successfully.

CREST's expertise in this field really shone on this project.

Lee Duffield, CREST Contracts Director

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Cleanroom installation for pharmaceuticals

Fully flush vision panels for cleanrooms

Fire-Rated Cleanroom Partitions for Modular Building

Catfoss Group Manufacturing

Background:

As part of an ongoing expansion for an R&D manufacturing campus, Catfoss Group Manufacturing were constructing a modular building and required a number of clean fire-rated areas.

Process:

As an offsite modular construction, site surveys could only be completed once everything was in place on site, where CREST then worked efficiently to complete the necessary surveying and design tasks prior to installation.

Solution:

Working to a tight programme of works, CREST supplied and installed approximately 250m² of fire-rated partitions, 80mm thick Kingspan Mineral Fibre Cored panels were used to create several clean areas with a corridor.

The team also installed 8 no. 60 minute fire-rated double hinged personnel doors, which were compliant to DDA standards. This was in conjunction with firestopping products to the partitions to ensure a fire-rating of up to two hours throughout.

Stancold worked well, especially in the conditions you were working in

Andrew Noble, Catfoss Group Manufacturing

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Warehouse fire-rated clean partitions, Coventry

Fire-rated clean partitions for warehouse

Medical Cleanroom Partitions

Healthcare Science Manufacturer

Background:

After successfully working with our client’s previous end user at a medical technology company in 2017, CREST were asked to complete a second cleanroom partitioning project on the same site.

Process:

As this was a complex project and was to be conducted in a live environment, the CREST team attended numerous site visits with the cleanroom contractor and the medical tech end user to discuss finer details of the installation process. Working closely with both parties provided the necessary support in the pre-construction stage of the project.

Project Delivery:

As per the client’s requirements, CREST dismantled and removed the temporary walls in place and then erected 500m² of new cleanroom partitions using Kingspan QuadCore 80mm panels integrating a hinged personnel access door.

Using our team’s strong expertise of working in a live environment, appropriate measures were implemented to ensure no construction debris left the area outside of the temporary screens and panels were cut away from the construction area, allowing the client’s working operations to continue as normal.

Communication from CREST is always brilliant.

Simon Buchanan, Haldons Construction

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Cleanroom partitions with hinged personnel door

Cleanroom 80mm partitioning on site at medical device manufacturers

Cleanroom partitions for medical device manufacturers

CL3 Laboratory

Immunomodulating Medicine Manufacturer

Background:

CREST worked with a regular cleanroom contractor partner and an Oxford based pioneering biotechnology company that manufactures immune system medicines, to complete the specification, design and construction of a CL3 laboratory.

Process:

As a CL3 facility, every element of the laboratory envelope had to be carefully considered to ensure that the demanding specification could be achieved.

With an intricate design layout to follow, a number of amendments were made to our scope before CREST’s project manager visited site to undertake a detailed survey.

Project Delivery:

Our expert team, utilised the high-specification Puracore cleanroom system, along with a flush vision panel and semi-flush clamp frame door for this complex build.

Due to the facility’s negative pressure, it was paramount that all junctions and construction details within the laboratory structure were carefully thought-out to prevent contaminated air from getting in. A vinyl weld was combined with a uPVC white food-safe laminate panel finish to ensure the most secure seal to the lab.

This was another successful contract completion for the team, demonstrating our unrivalled technical understanding of critical environments.

A great project to work on, diversifying our strengths once again to achieve client satisfaction.

Mark Kendrick, CREST Cleanroom Expert

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Aeronautical Cleanroom Suite & Firewall Partitions

Aeronautical Research & Development

Background:

Using our unique experience of cleanroom design and construction and fire-rated enclosures, CREST were awarded the project after winning a competitive tender through a principal contractor.

Process:

The suite of new cleanrooms were built to Grade D classification and the fire-rated enclosures were designed to be clean not classified.

Project Delivery:

We installed 6m high freestanding walls with integrated flush cleanroom windows connected to an aluminium T-Bar suspended ceiling grid which formed the plenum and low-level return air cooling coils.

The return air ducts were formed using 50mm FM approved Puracore cleanroom walls to a height of 6m and we also provided temperature-controlled cleanrooms with Eurobond panels to a height of 8m.

The integration of a 4.5m high viewing gallery into the walls with rapid roller doors below and for interlocked doors presented a significant challenge, one which we met with enthusiasm.

The fire rated enclosures were fitted with roller shutter doors and hinged doors certified to LPS certification. Various size semi-flush Puracore doors were installed along with rapid rise doors ranging in size (3.5m high x 3.0m wide and 5.0m wide x 5.5m high), supported laterally by the Puracore walls with no need for additional structural steel members.

As a result of the team’s expertise, the installation was completed in 21 weeks, leaving the client satisfied with the final product.

This project showcases our cleanroom expertise.

Paul Towse, Project Manager

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Puracore honeycomb panels for aeronautical research cleanroom

Aeronautical cleanroom facility installed by Stancold

Cleanroom installation including flush cleanroom windows

Cleanroom panels in viewing gallery for aeronautical research

ISO 7 Cleanroom

Monmouth Scientific

Background:

Having built a strong relationship with clean air solutions experts, Monmouth Scientific, CREST were appointed to work alongside them on a new cleanroom for a high-end precision mouldings manufacturer for their new injection moulding facility.

Process:

To align with updated product specifications and meet stringent regulatory requirements, the new cleanroom facility had to achieve ISO Class 7 certification in accordance with ISO 14644-1 standards.

The cleanroom was set to be split into three separate rooms, each with personnel doors, and a sliding door for ease of access

Project Delivery:

Due to our team’s extensive product knowledge, they were able to install thicker ceiling panels to comply with the specification of the HEPA air filtration system. Collaborating with a trusted expert such as Monmouth Scientific was essential to guarantee system integrity, regulatory compliance and long-term reliability of the clean air environment.

Across the cleanroom itself, a laminated finish was applied to the panels for ease of maintain a clean and sterile environment.

Furthermore, the team installed vision panels in each room, making it easier for staff and clients to oversee production without needing to enter the cleanroom. The vision panels would allow for enhanced day-to-day monitoring, support smoother communication and provide a clear view of operations at a glance.

The fast-track contract, which was completed in under a week, left both Monmouth Scientific and their client satisfied.

Installer team were very good and end user was very happy.

David Pomeroy, Monmouth Scientific

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Triple Compartment Cleanroom

BSRIA

Background:

CREST were approached by BSRIA, a construction research and testing organisation, who were opening a new facility and required a cleanroom design and build solution.

Process:

Due to the large cleanroom design and build scope, the team worked closely with the client to create a seamless construction plan in order to meet expectations on time management.

CREST’s highly skilled team installed numerous doors to accommodate BSRIA’s needs. This included four-hinged clamp frame personnel doors, a hinged emergency exit door, and a heavy-duty sliding chiller door. Each door would enable ease of access for personnel and large pieces of equipment, whilst maintaining smooth operations throughout the facility.

Additionally, seven single vision panels were installed to allow for visibility from outside the cleanroom in order for safe observation without disrupting the controlled environment, helping maintain sterility and containment. This would also improve communication and safety by providing clear visibility between spaces, reducing unnecessary entry and contamination risks.

Project Delivery:

CREST’s unrivalled knowledge left the client satisfied with the outcome and ready for them to begin their accredited testing in each of the installed rooms.

We were all hugely impressed with the job, everything was done very well. If we ever have need of such work again I would definitely use you.

June Davis, BSRIA

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Cleanroom Partitions

Pharmaceutical Distributor

Background:

CREST were appointed to work with an interior fit-out contractor to complete the internal fit-out of the space of a pharmaceutical distributor’s warehouse.

The family-run business, specialising in pharmaceutical products and clinical trials, expanded their operational warehouse to begin the new phases of its UK distribution strategy.

Process:

As a result of the stringent nature of pharmaceutical production and distribution, the cleanroom was required to meet strict sterile conditions throughout.

As part of the envelope specification between the offices and main warehouse, considerations were made for U-values and a FR60 rating to maintain the safety of staff and product integrity.

Project Delivery:

CREST worked collaboratively with both the client and contractor to develop the internal fit-out design smoothly. This resulted in a design that accommodated the building’s existing structure, including the roof external fittings, seamlessly.

The team’s expert knowledge and proactive nature allowed them to put in place preventive measures, such as aluminium tread plate protection, to ensure the forklifts and machinery that were in operation wouldn’t cause damage.

Working in a live environment required the team to work to a tight schedule in order for operations to continue with minimal disruptions.

Not only was the client left satisfied with the result, but the team were also able to build a long-standing relationship with the interior fit-out contractor.

Thank you for your efforts, well executed and looking very professional.

Greg Howarth-Hough, Envoplan

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Hygienic panels for pharmaceutical distributor in Watford

Hygienic environment for pharmaceutical distributor

Internal panel fit-out with tread plate protection

Freezer Storage for Carbon Fibre

Tygavac

Background:

Tygavac, part of the Airtech Advanced Materials Group, partnered with CREST to deliver a high-performance temperature-controlled build solution for carbon fibre prepreg, a woven composite used in the medical, automotive and motorsport industries.

To maintain product integrity and extend shelf life, carbon fibre materials must be stored consistently below -20°C.

Process:

After a comprehensive site survey, CREST proposed the design and build of a turnkey freezer store that measured at 470m³.

The solution included high-density pallet racking for efficient handling of carbon fibre rolls, a reinforced and insulated concrete floor with an underfloor heating system to prevent frost damage and a full protective infrastructure to support operational safety and long-term performance.

Project Delivery:

CREST’s expert team installed a custom-integrated door to allow for the facility’s forklift to have easy access.

For the refrigeration system, evaporators and two condensing units were integrated to ensure even air distribution and stable sub-zero conditions to adhere to the composite material storage requirements.

As part of the turnkey package, all mechanical, electrical and plumbing systems were installed by CREST.

To ensure precise performance monitoring, an RDM Data Manager was installed, enabling local and remote control of storage conditions via desktop or mobile app.

This allows for consistent temperature management and full traceability of the carbon fibre materials.

CREST delivered an exceptional solution, showcasing our expertise and precision by designing and building a freezer storage facility that meets the demanding requirements of carbon fibre preservation, ensuring consistent performance, safety and long-term reliability at every stage.

New technology enables control of the store temperature remotely.

Gary Howells, Project Manager

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ISO 8 Cleanroom Build

Snazaroo

Background:

Due to continuous growth in product ranges and increase of global demand, our customer required an ISO 8 cleanroom for the mixing of fine powder pigments and cosmetic ingredients to produce their 100% skin friendly paraben and fragrance-free paints.

Process:

Our scope of works consisted of the design and build of a semi-flush ISO 8 cleanroom, accommodating machinery and air vents supplied by their preferred M&E contractor, complete with a built-in atrium functioning as a high care changing area.

Project Delivery:

CREST successfully delivered a complete cleanroom envelope that was value-engineered to suit the client’s requirements. This included 4 filter units, 3 vision panels and transparent personnel doors for better light conditions and security reasons.

You are very professional. We are very pleased with the installation and would recommend you to anyone.

Adrian Ryan, Snazaroo

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Research Laboratories

Johnson Matthey

Background

Johnson Matthey are a leading international chemicals and precious metals company headquartered in London.

Requirement

Stancold were contracted to build 2 research laboratories the area of 72m² and 36m², ladder enclosure and suspended ceiling in a high security environment.

Solution

In the absence of a structural beam, Stancold have created a specialist galvanised angle to suspend the ceiling from. The walk-on ceiling has provided the customer with easy access to their pipework ring main, thus reducing potential downtime in production areas. The ladder enclosure has provided excellent dust control which is of particular importance due to the product inspection requirements.

I will certainly recommend you and your installation team.

Mark Wall, Johnson Matthey

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