7 Ways to Keep Construction Workers Safe on Cleanroom Projects

By Bill Polen, NE Regional Safety Manager for Performance Contracting

Cleanroom construction is unlike any other type of building work.

Whether you’re supporting semiconductor manufacturing, biotechnology, or pharmaceutical research, these ultra-controlled environments require specialized expertise, not just in how they’re designed, but in how they’re built. Safety on cleanroom projects goes beyond hard hats and harnesses. It’s about protecting both the construction team and the integrity of the space under construction.

Cleanroom construction often occurs within operational facilities or high-sensitivity settings, where dust, vibration, and contamination must be strictly controlled. However, these environments also pose real risks to construction crews, from working in confined areas and elevated platforms to navigating complex mechanical systems and specialized materials. Here’s how we keep both our teams and the cleanroom space protected from day one.

1: Education

Comprehensive Cleanroom Training for Every Worker

  • Before entering a cleanroom jobsite, every crew member must receive specialized training, not just on standard safety procedures, but on cleanroom-specific protocols. This includes gowning steps, contamination risks, movement restrictions, and how to handle sensitive materials or equipment.
  • Cleanrooms are precision environments, and even minor oversights, like tracking in dust or mishandling equipment, can compromise the project. Training builds awareness and creates a safety-first mindset tailored to the cleanroom context.

2: Equipment

Wearing the Right PPE for the Right Phase

  • Personal protective equipment (PPE) is always essential, but in cleanroom construction, it must evolve with the project’s progress. Early in construction, workers may use typical gear like hard hats, gloves, and eye protection. As interior systems come online, PPE shifts to include Tyvek suits, non-shedding boot covers, hair nets, face masks, and even respirators or anti-static garments—depending on the classification of the space.
  • This equipment not only protects the workers from exposure to particulates or chemicals, it also prevents them from becoming a source of contamination.

3: Contamination

Keeping Dust and Debris Under Control

  • Unlike typical construction sites, where dust is an inconvenience, in cleanrooms it’s a critical concern. Contaminants as small as a few microns can disrupt manufacturing processes, spoil sensitive products, or delay commissioning.
  • We use HEPA-filtered vacuums, install sticky mats at entry points, and isolate activities like cutting or sanding. Regular cleaning is part of the daily workflow—especially in phases leading up to certification and validation.

4: Protocols

Controlling Access and Following Gowning Procedures

  • A cleanroom isn’t just a space, it’s a system. Maintaining that system starts with controlling how people enter and move through it. We work with clients and designers to clearly define access paths and transition zones. That includes setting up temporary gowning areas, posting clear instructions, and ensuring every person on-site understands proper gowning protocol.
  • Access points are minimized, and once cleanroom finishes are underway, our team adheres to strict directional flows and traffic rules to prevent cross-contamination.

5: Materials

Using Only Cleanroom-Approved Materials

  • Material selection isn’t just an architectural decision—it’s also a safety and performance concern. Construction crews must know what materials are approved for use in different cleanroom zones and why. That means only using pre-approved low-VOC sealants, non-shedding insulation, and components that won’t compromise air quality or introduce particulates.
  • Introducing the wrong material, no matter how small, can jeopardize certification or require costly rework. Our teams are trained to double-check specs and coordinate closely with quality assurance teams on-site.

6: Procedures

Following Enhanced MEP Safety Procedures

  • Cleanrooms rely on some of the most complex MEP systems in construction, from high-volume air handling and humidity control to pressurized piping, specialty gases, and sensitive electrical gear. Working in these environments demands a higher level of coordination and caution.
  • Our crews follow rigorous lockout/tagout (LOTO) protocols, are trained in confined space safety, and conduct system-specific safety reviews before beginning any mechanical or electrical work. Nothing is left to chance when dealing with systems that support mission-critical operations.

7: Communication

Reporting Damage or Variations Immediately

  • No jobsite is perfect, but cleanroom projects demand swift, transparent communication. If a sealed wall is nicked, a vapor barrier is torn, or a panel is improperly installed, our workers are empowered and expected to report it immediately. We isolate the issue, tag it, and work with project leads to develop a repair plan.
  • Proactive reporting saves time and protects the long-term performance of the space. Cleanroom certification depends on precision, and that starts with accountability.

Building With Integrity and Safety in Mind

At PCI Cleanroom Contracting, our cleanroom work is guided by a dual commitment: to protect the workers who build these complex spaces and to ensure those spaces meet the stringent standards of the industries they serve. Safety isn’t just about compliance, it’s about getting it right, every time.