Pragmatic - Class 10,000 Cleanroom

Project Background

Semiconductors are essential to our everyday lives, enabling advances in communication, computing, healthcare, clean energy, and countless other areas. Pragmatic is a world leader in semiconductor innovation with its revolutionary technology that doesn't rely on silicon. 

In 2022, we started working with the company to design a Class 10,000 cleanroom, which is currently being installed at a new 175,000ft² fab facility in Pragmatic Park, Meadowfield, County Durham. The factory will make up to 10 billion RFID plastic chips yearly on 300mm polyimide flexible substrates. Unique to this project, Pragmatic wants the modular cleanroom to be replicable across its customer's sites. The business plans to install over 100 fabs globally in the next two years. 

Our Solution

We initially developed a series of detailed 3D engineering designs to match the specifications provided by the client. Through this process, we identified several measures to minimise client costs and improve the facility's overall efficiency. These measures included:

• Demountable wall panels to facilitate future tool moves within a tight footprint
• The creation of a specialist steelwork structure to support the walk on ceiling
• Mechanical and electric services for the cleanroom and toolset 

Our dedicated team of process engineers and pipefitters are now managing the on-site build phase from start to completion. We have partnered with specialist contractors to provide elements such as the offsite fabrication of the steelwork structure and the E60 fire-rated cleanroom fabric. This has required strong project management to coordinate the contractors across the various stages of the build.

Other key features incorporated into the facility include:

• Ceiling height set to account for the Muratec Robot system
• Bespoke walk-on ceiling that meets E60 rating
• E60 glazing to showcase toolset automation and Muratec automated transport system
• Secondary steelwork support to provide a mount location for Muratec AMHS with OHT and FOUP storage - a UK first

Outcomes

The final Class 10,000 cleanroom will be a showpiece for the UK's semiconductor industry, demonstrating cutting-edge technology that delivers an end product in just two weeks.  

Our forward-thinking approach to the design and build benefits the client in the following ways:

• Future cost savings relating to operations and maintenance
• Expedited project delivery
• Replicable modular design supporting Pragmatic's future growth ambitions
• Flexible tool access supporting delivery dates