Cleanrooms have controlled environments where even the smallest particles, microbes, or chemical contaminants can jeopardize processes. Whether you run a pharmaceutical lab, electronics manufacturing unit, or food packaging facility, the quality of your cleanroom walls plays a vital role. They are responsible for upholding hygiene, durability, and compliance.

Traditionally, FRP and drywall were used for walling in controlled environments. They, however,  fall short in terms of long-term durability, contamination resistance, and cost-effectiveness. This is where PVC cleanroom panels step in as a superior alternative. Let’s explore why it’s time to replace FRP or drywall with PVC panels in your cleanroom. Plus, find out how this upgrade can enhance efficiency, compliance, and cleanliness.

The Limitations of FRP in Cleanrooms

FRP panels were once popular due to their relatively affordable installation. However, they come with several drawbacks:

Seam Issues 

FRP installations require adhesives and trims, which often leave seams that can trap dust, microbes, and contaminants. Over time, these gaps compromise the sterile nature of a cleanroom.

Delamination 

Moisture and cleaning chemicals can weaken the adhesive, causing FRP panels to peel or bubble away from the wall surface.

Porosity  

FRP isn’t fully non-porous. This makes it difficult to sanitize effectively, leaving behind potential contamination risks.

Rotting

As moisture seeps in through the porous surface of FRP panels, it gets absorbed into the wooden backer boards. This results in damp patches on the walls and rotting of the backer boards. 

High Maintenance 

Repairing or replacing damaged FRP sections is costly and time-consuming.

Why Drywall Doesn’t Work for Cleanrooms?

Drywall may be inexpensive upfront, but it is one of the least suitable options for cleanroom construction.

Moisture Sensitivity 

Drywall easily absorbs water, leading to mold and mildew growth, which is unacceptable in controlled environments.

Weak Surface 

Drywall surfaces wear out quickly, especially under frequent cleaning and disinfecting.

Particle Generation 

Cracks, chips, and scratches release dust and particles, disrupting the controlled environment.

Short Lifespan 

In high-maintenance environments like cleanrooms, drywall simply doesn’t hold up.

Why PVC Cleanroom Wall Panels Are the Better Choice?

PVC panels are specifically engineered for sterile and sensitive environments, making them the perfect upgrade for cleanrooms. Here’s why they outshine FRP and drywall:

Seamless, Hygienic Design

PVC cleanroom wall panels use a tongue-and-groove interlocking system, eliminating the need for adhesives or trims. This creates smooth, seamless walls that leave no space for dust, bacteria, or chemicals to accumulate.

100% Moisture and Mold Resistant

Unlike FRP or drywall, PVC panels are completely non-porous. They don’t absorb moisture, which prevents the growth of mold, mildew, and bacteria, which is crucial for industries that demand strict hygiene.

Chemical and Corrosion Resistance

Cleanrooms often require aggressive cleaning agents for sterilization. PVC panels resist corrosion and chemical damage, ensuring the walls remain intact and easy to sanitize.

Impact Resistance and Durability

PVC wall panels are built to withstand impacts without cracking or chipping. Their durability ensures a longer lifespan with minimal repair costs.

Low Maintenance

Thanks to their smooth, washable surface, PVC panels are simple to clean. A quick wipe-down with disinfectant is enough to restore them, unlike FRP or drywall that demand intensive scrubbing or repairs.

Quick and Cost-Effective Installation

PVC panels are lightweight and easy to install directly over existing surfaces, reducing downtime for your facility. The interlocking system speeds up installation and lowers labor costs.

Compliance-Ready

Many industries like pharma, biotech, food, and electronics require hygiene and safety compliance. PVC panels support compliance thanks to their sterile, easy-to-clean, and durable construction. Plus, they are ASTM-certified, CFIA and FDA-compliant, and Class-1 fire-rated. 

Long-Term Cost Comparison between PVC and Traditional Solutions

While FRP or drywall might look cheaper at first glance, they become more expensive over time. Here’s why:

• FRP requires frequent maintenance due to delamination and seam contamination.
• Drywall deteriorates rapidly, needing costly repairs or replacements.
• PVC panels have a higher initial investment but pay for themselves through durability, minimal maintenance, and compliance assurance. 

In the long run, PVC panels provide greater value for money by saving significantly in the final cleanroom wall panel cost. 

Applications of PVC Cleanroom Wall Panels

PVC panels are versatile and suitable for a wide range of cleanroom environments, including:

• Pharmaceutical production units
• Biotech labs
• Medical device manufacturing
• Food and beverage processing
• Electronics and semiconductor facilities
• Research laboratories

Frequently Asked Questions on PVC Cleanroom Panels

Can PVC panels be installed over existing FRP or drywall walls?

Yes. PVC panels directly attach to FRP, drywall, concrete, or other existing surfaces. This reduces demolition costs and speeds up the renovation process.

Are PVC panels fire-resistant?

Duramax PVC panels are Class 1 fire-resistant and can withstand an hour of fire and flame without damage or releasing toxic gases. 

How do PVC panels help in maintaining cleanroom classifications?

PVC panels offer a seamless, non-porous surface that minimizes particle accumulation. This helps maintain the controlled environment required for cleanrooms.

Do PVC panels require special cleaning products?

No. PVC panels can be cleaned with standard disinfectants and cleaning agents used in sterile facilities. Their chemical resistance ensures they don’t degrade during repeated sanitization.

What is the lifespan of PVC panels compared to FRP or drywall?

PVC panels can last several decades with minimal upkeep, whereas FRP may need repairs every few years, and drywall often requires frequent replacement. Duramax PVC panels are guaranteed to last 4x times longer than FRP panels without deteriorating, peeling or mold formation. 

Are PVC panels environmentally friendly?

PVC panels are recyclable and designed to reduce long-term waste by eliminating frequent replacements.

Final Thoughts

Replacing FRP or drywall with PVC cleanroom panels is not just a smart decision. It’s an investment in compliance, hygiene, and long-term savings. With their seamless design, resistance to moisture and chemicals, and unmatched durability, PVC panels are tailored to meet the stringent demands of cleanrooms.

Check out the PVC panels from Duramax that are made to last and perform. Duramax is one of the leading PVC cleanroom wall panel suppliers in the USA. Our panels have a shelf life of 100 years, backed by a limited lifetime warranty. Plus, we offer factory-direct pricing for these panels. Ask for a free sample now!