Laboratory design for containers – layout, cleanroom, GMP-conformant

Specialist engineering design of a lab container begins with the standards matrix: which ISO class (14644-1), which ventilation grade (DIN 1946-7), which containment level (TRBA 100, BioStoffV) and which test standard (ISO 17025) apply to the project? That definition determines layout, HVAC sizing, utilities routing and transport dimensions.

Our design process starts with a structured needs analysis: workflows, instrument list, containment level, utilities demand and site conditions. On that basis we produce CAD floor plans with zone planning (cleanroom, airlock, plant room, hazardous-substance store), an MEP concept with air-change calculation and 3D visualisation for clash detection. Every design decision is documented in a design report with a standards reference.

Container design differs from building design because of transport restrictions: maximum module width 2.55 m (standard) or 3.0 m (abnormal load), maximum length 12 m per module, maximum height 3.0 m for road transport. All components — HVAC units, fume cupboards, safety cabinets — must pass through container doors or are retrofitted as individual items.

Our structured design process ensures that every detail is considered and that you ultimately receive a laboratory that exceeds your expectations.

Phase 1: Needs analysis and concept development

In the first phase we hold intensive discussions with all stakeholders — from laboratory managers and facility managers through to the scientists who will work in the laboratory daily. We analyse the planned workflows, the required instruments and the specific safety and hygiene requirements. On that basis we develop initial concept drafts, which we discuss and refine with you.

Phase 2: Preliminary design and scheme

Once the concept is agreed, the actual design work begins. Our engineers produce detailed floor plans, sections and elevations. We design the technical infrastructure — from power supply through utilities (gases, water, compressed air) to ventilation and HVAC. Particular attention is paid to compliance with all relevant standards and regulations, especially DIN EN 12128 for laboratories, ASR A3.6 for ventilation and the Workplace Ordinance.

Phase 3: Detailed design

In the detailed-design phase every detail is fixed. We prepare bills of quantities, define materials and qualities and coordinate the various trades. Our 3D models enable precise clash detection, so that problems can be identified and resolved already in the design phase.

Phase 4: Support during implementation

We remain at your side during construction. We monitor execution, coordinate the companies involved and ensure that implementation follows the design exactly. Where change requests or unforeseen challenges arise, we respond flexibly and find pragmatic solutions.

Designing lab containers places particular demands on our engineers. Unlike conventional laboratory buildings, all technical systems must be accommodated in a very compact space without restricting functionality. At the same time the containers must remain transportable and meet the strict requirements of road transport.

Our long-standing experience in container-laboratory construction enables us to implement even complex requirements in compact units. We have developed solutions for:

• BSL-2 and BSL-3 laboratories with controlled negative-pressure zones
• Cleanroom laboratories to ISO classification
• Analytical laboratories with sensitive measuring equipment
• Chemistry laboratories with fume cupboard systems and hazardous-substance storage
• Microbiological laboratories with specific hygiene requirements
• Mobile research units for field studies

Stick-build projects tie design capacity for months to site coordination, variation management and trade clashes. Modular laboratory design defines all interfaces — ventilation to DIN 1946-7, cleanroom to ISO 14644, containment to TRBA 100, ATEX to EN 60079 — already in the scheme stage, because the container is completed and transported as a closed system from the works.

For pharma and biotech lab containers we design GMP-conformant pressure cascades and Annex 1 containment; for research and university laboratories flexible layouts with expandable module connections. ISO 17025 testing laboratories receive documented measurement chains and calibratable environmental conditions from the start of design.

Every design service is documented against a standards matrix. For BSL-3 laboratories, TRBA 100, BioStoffV and controlled negative-pressure zones apply (typically −25 Pa to the airlock, −50 Pa to the exterior). GMP projects reference EU-GMP Annex 1 (as of 22.08.2022) with a Contamination Control Strategy. ATEX zones to EN 60079 require separate design of ignition sources, ventilation and explosion protection.

MEP design covers air-change calculation to DIN 1946-7, utilities supply (process water, demineralised water, technical gases), drainage with hazardous-substance separation and electrical load calculation to VDE. All values feed into manufacturing drawings for works fabrication in Albstadt — without redesign on site.

For cleanroom design to ISO 14644 we calculate particle limits (Class 5–8), recovery time to ISO 14644-3, pressure cascades between zones and the HEPA filter concept (H13/H14). For BSL-3 we design directional airflow with negative-pressure zones, personnel airlock and bag-in-bag-out filter change. Every calculation is recorded in the design report with input parameters, assumptions and result.

ATEX zone design to EN 60079 covers zone classification (Zone 0/1/2), ignition-source analysis, selection of Ex-protected equipment and a ventilation concept for flammable gases. Zone classification is colour-coded in the CAD floor plans and taken into account in the electrical design.

ISO 17025 design covers workstation definition with environmental tolerances, traceability of the calibration chain and documentation of influence quantities on measurement uncertainty. Each workstation receives a unique measurement-station ID in the room data sheet.