Design – Case Study 3

17,500 SF CLEANROOM/LABORATORY R&D FACILITY RENOVATION-NEW JERSEY


Client Need

Design-Case-Study-3-Photo

The renovation of approximately 17,500 SF of an existing 20,000 SF manufacturing facility required engineering and design support for our design/build construction contracting partner. Our role was to provide working schedules and drawings including air and water side riser diagrams for pricing and construction in conformance with a tight construction schedule. Our scope of work included new mechanical, process and electrical systems to support the new facility including support of equipment in the new combination cleanroom/laboratory spaces.

Design Features

  • Basis of Design Setpoints: 71 °F (± 2 °F) and 40% RH (± 10% RH) year round.
  • Humidity Control Room Setpoint: 73 °F (±2 °F) and 72% RH (±4% RH) year round.
  • Full sequence of operations for all new equipment including all interface points with existing equipment and systems.
  • New combination cleanroom and laboratory spaces.
  • New 10,000 CFM make-up air handling units [2] provide make-up air to facility, new air handling units [2] dedicated to freeze dryers, new lab exhaust fans [3], relocated exhaust air scrubber from old facility to new facility.
  • New 260 ton air cooled scroll chiller plant including secondary chilled water and process cooling water heat exchangers and pumps.
  • Relocated 60 ton process air cooled scroll chiller plant from remote location; 2 chillers and pump.
  • Provided new, stand-alone ventilation systems for two new Chemical Storage Rooms.
  • 26 Lyophilizers, 17 Captive Air Hoods, 14 Fume Hoods, 3 Walk-In Freezers and over 40 Ovens distributed throughout clean room areas.
  • New 2,500 MBH gas fired boiler plant serving make-up air handling units and reheat coils.
  • New lab exhaust fans; 16,400 total CFM.

Design Benefits

  • Critical research areas have tightly controlled, year round temperature to ±2.0 °F and relative humidity to ±10% RH.
  • Humidity Control Room has tightly controlled, year round temperature to ±2.0 °F and relative humidity to ±4% RH.
  • Cascade pressure relationship between critical and noncritical areas to prevent infiltration and molecular contamination.
  • Achieved a robust R&D facility with high heat load equipment (Lyophilizers & Ovens) and high ventilation requirements (fume hoods) capable of operating continuously year round , while maintaining strict environmental criteria.
  • Met construction contracting partner’s tight schedule and deadlines.