Lab container modular construction – build, modularity, expandability

Manufacturing a Planexus lab container follows a defined process: steel-frame welding and corrosion protection, wall and ceiling installation, electrical installation to VDE, ventilation plant to DIN 1946-7, utilities supply, interior fit-out with laboratory-grade surfaces, equipment installation and final inspection. Every step is documented in the manufacturing protocol.

The container modules are prefabricated at specialised partners; final assembly and quality control take place at the Albstadt works. Electrical testing, ventilation leak testing, utilities-line pressure testing and FAT (Factory Acceptance Test) run there under controlled factory conditions — independent of weather and site delays.

Modular construction enables parallel manufacturing of several modules: while module 1 is in final assembly, module 2 is already being welded. For multi-module plants (e.g. a BSL-3 complex with personnel airlock, laboratory and plant room) this shortens overall manufacturing time by 30–40 % compared with sequential one-off production.

At the heart of every Planexus lab container is a robust steel frame that withstands the highest loads. The frame construction is designed so that it survives transport by lorry, ship or rail without difficulty and guarantees absolute stability even when containers are stacked.

Wall build-up and insulation

The wall elements consist of highly insulating sandwich panels 80 to 120 mm thick. The core of polyurethane rigid foam or mineral wool provides excellent thermal insulation (U-value down to 0.20 W/m²K) and meets the highest fire-protection requirements. Surfaces are optionally powder-coated steel, stainless steel or HPL-coated boards — depending on requirements for chemical resistance and cleanability.

Floor build-up

The floor of our lab containers is designed for high point loads and readily accepts even heavy laboratory instruments. A multi-layer build-up with steel substructure and insulation forms the basis for various floor coverings. For laboratories with elevated chemical-resistance requirements we use specialist laboratory floors of epoxy resin or PVC with welded seams.

Roof construction

The roof is decisive not only for weather resistance, but also for the integration of plant. Our roof constructions provide sufficient space for HVAC units, ventilation plant and extract-air routing. Thermal separation between roof and interior prevents condensation and ensures a stable indoor climate.

Our manufacturing process follows a structured sequence that guarantees the highest quality with efficient production. Every work step is documented and inspected, so that we can hand over a product that meets our strict quality requirements.

Prefabrication of components

The individual components — steel frame, wall elements, roof elements — are prefabricated in specialised workshops. This enables precise manufacturing under controlled conditions and considerably shortens on-site assembly time. The steel structure is grit-blasted and provided with a multi-layer corrosion-protection coating that offers decades of protection.

Assembly and fit-out

Assembly takes place in a covered hall, protected from weather. The prefabricated elements are joined, the technical installations are introduced and the interior fit-out is carried out. Our experienced assembly team works to detailed work plans and ensures that every detail is correct.

Final inspection and acceptance

Before dispatch, every lab container undergoes a comprehensive final inspection. We test all technical systems, carry out leak tests and document the condition photographically. Acceptance takes place together with the customer, so that you can satisfy yourself of the quality on site.

Our lab containers are available in various standard sizes that follow common container dimensions and thus enable trouble-free transport:

• 20-foot container: approx. 6.0 x 2.4 m (14.4 m² usable area)
• 40-foot container: approx. 12.0 x 2.4 m (28.8 m² usable area)
• Overwidth containers: up to 3.0 m width (increased transport requirements)
• Double-storey plants: for maximum space utilisation
• Multi-module complexes: by joining several modules

On request we also manufacture special sizes that are matched exactly to your spatial conditions. Speak to us — together we will find the optimum solution.

Modular construction enables several life cycles: after a project ends, containers are cleaned, decontaminated and prepared for the next deployment. Thermal insulation (U-value down to 0.20 W/m²K) considerably reduces energy demand for HVAC systems to DIN 1946-7.

At the end of service life, steel frames and sandwich panels are sent for recycling. Material evidence (steel grade, insulation, coating) is recorded in the works documentation.

Works manufacturing is adapted to the intended use. For pharma and biotech lab containers we manufacture Annex 1-conformant cleanroom modules with an ISO 14644 leak-tightness concept. Public-health laboratories receive BSL-2/3 modules with TRBA 100-conformant airflow and BioStoffV documentation.

Ventilation plant to DIN 1946-7, ATEX execution to EN 60079 and GMP surfaces to Annex 1 are integrated from the works and recorded in the FAT. ISO 17025 testing laboratories receive low-vibration floor constructions and calibratable environmental zones. Every module leaves the works with complete works documentation.

The steel-frame construction is designed to a structural calculation to DIN EN 1990: point loads up to 500 kg/m² for heavy laboratory instruments, wind loads to DIN EN 1991 for roof plant (HVAC), transport loads to ISO 1496 for road and sea transport. Welds are inspected to DIN EN ISO 5817 Class B.

BSL-3 manufacturing requires airtight construction with leak-tightness evidence (leak rate < 0.5 m³/h·m² at 50 Pa), HEPA dual filtration and pressure-held wall penetrations. GMP manufacturing requires smooth, disinfectable surfaces without pores and documented material certificates (3.1 to EN 10204).

The location of the Albstadt works (A81, Albstadt-Ebingen exit) enables same-day delivery to Stuttgart, Tübingen and Reutlingen. For lab containers Stuttgart and the surrounding area, overnight logistics is unnecessary — transport and installation on the same day.