Confidential Semiconductor Manufacturing Client

Fab 8.1 S19 Basebuild

Highlights

Overview

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Project Highlights

Capacity upgrades to increase predictability and connection with end user operations in this existing semiconductor manufacturing facility.
Basebuild work included upgrades to an existing PCW system, acid waste treatment systems, process mechanical (vacuum, chilled water, acid, exhaust, etc.), power capacity upgrades, bulk gas systems, and cleanroom buildouts.
BIM and clash detection was leveraged to ensure the project was conflict free.
Executed substantial off-site fabrication.
Due to early involvement in planning processes, we delivered pricing the was 17% less than the estimated last price paid by this customer using a traditional design-bid-build delivery model.

Confidential

Owner/Client

Jacobs

Architect

Malta, New York

Location

August 2019

Completion Year

10,000

Square-Foot Cleanroom

2,200

Linear Feet of Pipe

52,000

Gallons of Total Volume in Pipes

Innovative Capacity Upgrade: Seamless Integration of Advanced Process Cooling Water Systems in a Live Semiconductor Facility

Advanced Use of BIM for Seamless Integration

Our team utilized Building Information Modeling (BIM) for routing 24” stainless steel piping through this active semiconductor facility, ensuring minimal conflicts throughout design and construction. We employed delegated design for support steel, enhancing the precision and efficiency of the installation process. In the end, our team achieved a flawless safety record with zero incidents, highlighting the effectiveness of BIM in planning and execution.

Significant Capacity and Infrastructure Enhancements

We installed over 2,200 linear feet (LF) of 24” welded 304L stainless-steel pipe, along with (4) 250HP pumps, (3) 3,500GPM heat exchangers, and additional components. We implemented a 12” PCW temporary bypass to facilitate hydrotesting, flushing, and commissioning, ensuring system readiness before full integration. Utilizing pre-fabricated steel frames for pump bases, the team streamlined the installation process and reduced on-site work. This resulted in a higher end-product and a safer work environment.

Complex System Upgrades in a Live Facility

We conducted four high-risk hot taps on live systems to integrate new and existing systems without disrupting production. This required close coordination with facility operations to manage over 100 live utility relocations and ensure no impact on production. The team carefully phased activities such as issued pipe stress analysis, structural steel, and support designs to maintain project momentum and meet tight schedules.