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Composites Manufacturer
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Composites Manufacturer


A leading composites company had secured a contract to develop and supply special polycarbonate cockpit canopies for front-line American fighters. A completely new class 10,000 facility was required in the shortest time possible with many unique features relating to working with high strength polycarbonate.

Close temperature and humidity control is essential, even though large ovens at 160ºC, to flatten and form the sheets, open into the clean room and a massive autoclave unit is also part of the process equipment.


The only available location for this facility was on the second floor of an existing office block which was connected by a bridge to the main works. Very shallow ducts within a small ceiling void had to be fitted to allow the 3m x 1.8m polycarbonate sheets to be moved around the area by special crane unit.

The major air handling plant and condensers were installed on the office block roof and supply and return ducts were fitted down both sides of the building so that each side of the clean room could be supplied separately.

Antistatic epoxy flooring was installed and the main areas enclosed in melamine faced composite panels. Special product entry flaps allow the rail system to carry sheets into different process areas and interlocked personnal air locks were fitted with automatic air showers linked to the main room supplies.

The facility was commissioned on time and fully meets operating standards.


Many special features due to the new processes and site restrictions are incorporated into the design. We were able to fit essential cleanroom features around the special materials handling and environmental needs without dramatic specials costs. The plant position and ductwork design is an excellent demonstration of how to fit a facility to an available area.

Other specialist Clean Rooms have been installed on this site over several years and we are continuing to supply new and modified units.

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  Clean Room Installation Services Ltd
9 The Metro Centre, Ronsons Way, St. Albans, Hertfordshire, AL4 9QT
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Clean Room Installation Services Limited specialise in Clean Room Construction, Cleanroom Installation, Clean Room Building, Cleanroom Design, Clean air enclosures, environmentally controlled enclosures, particle free atmospheres, temperature controlled environments, humidity controlled environments, Clean air environments also Cold rooms, Filtered environments, Air conditioned rooms, Sterile environments, Sterile rooms, Filtered rooms, we design and install Clean Rooms to BS 5295 standards, Class 100 rooms, Class 1000 rooms, Class 10000 rooms, Class 100000 rooms, Class C Rooms, Class D rooms, Class E rooms, Class F rooms, Class G rooms, Class H rooms, Class J rooms, Class K rooms, Class L rooms, Class M rooms, Clean Rooms to ISO standards, Clean Rooms to US Federal Standard 209E, including hardwall, softwall, walls can be PVC, plastic faced, vinyled, aluminium, stainless steel and can be fire rated or non fire rated. Our Clean Room designs include floors, ceilings, electrics, lighting, plumbing, ducting, all associated plant, transfer hatches, step over benches, interlocks, workstations, laminar flow cabinets, ducting, refrigeration and filtration, for the Pharmaceutical, Medical, Medical Device Manufacture, Packaging, Precision Engineering, Biotechnology, Veterinary, Plastics Moulding, Chemical, Food Processing, Research, Optical, and Aerospace industries, also for Universities and Facilities management companies,  which demand clean, air filtered and particle free environments. Supply of cleanroom furniture, clean room products, clean room equipment, clean room storage, such as shelving, storage bins, cabinets, trolleys, shoe racks, filters, hepa filters, benches, fan filter units, cupboards, seating, dispensers, lockers, vacuum and extraction systems, are also available.