In an 18 month and $18m effort, Nortek Air Solutions completed a interesting retrofit.
At the beginning of the project, a semiconductor leader in Rio Rancho, New Mexico, identified a decommissioned building to retrofit a state-of-the-art cleanroom.
To avoid substantially higher greenfield design and construction costs, the client needed a sustainable retrofit
With 130,000 sqft identified to turn into a Class 1000/ISO Class 6 cleanroom, the leader faced several challenges as they aimed to integrate a new Automated Material Handling System (AMHS) with high-specification load requirements.
To address these challenges, the semiconductor leader partnered with Nortek Air Solutions. This case study dives into the impact of CleanTrak ceiling systems, the advantages of leveraging BIM Revit expertise, and the critical factors in selecting the right cleanroom ceiling system.
Challenge: Retrofitting a decommissioned building
The semiconductor leader needed a partner that could deliver a new cleanroom ceiling design, as well as Automated Material Handling Systems (AMHS) loads that were not part of the original building.
To avoid substantially higher greenfield design and construction costs, the client needed a cleanroom partner that could substantially retrofit the cleanroom ceiling system in a challenging space.
Project specifications:
- Structural limitations: The existing building was not originally designed to support the cleanroom environment or the weight of the AMHS live loads.
- Environmental control requirements: A Class 1000/ISO 6 cleanroom demands precise airflow, filtration, and containment measures.
- Integration of modern technology: The installation of an AMHS required modifications to the ceiling grid and air handling systems to accommodate new loads and airflow patterns.
BIM Revit design and custom CleanTrak ceiling system
To address the retrofit challenge, a complete overhaul of the ceiling system was needed as well as a performance audit of existing air handlers.
Multiple Clean-Trak ceiling grids and plenum types, along with forced return-air chimneys (FRACs), were custom-designed.
The Nortek Air Solutions team provided critical building information modelling (BIM) Revit design services to incorporate these changes and successfully re-purpose an existing structure. The benefits of incorporating BIM included:
Accurate visualisation: Enabled stakeholders to preview design modifications and ensure proper integration before construction.
Error reduction: Identified potential clashes and inefficiencies early in the process, minimizing costly rework.
Seamless collaboration: Allowed architects, engineers, and contractors to work together in real time, ensuring a smooth transition from planning to execution.
The CleanTrak system was selected for its ability to accommodate custom plenum types, forced return-air chimneys (FRACs), and high-load capacities. Key benefits included:
Scalability and flexibility: Modular design allowed for easy customisation to meet the project specifications.
Enhanced load-bearing capacity: Supported the increased AMHS, loads without compromising the cleanroom’s ceiling integrity.
Optimised airflow: Integrated plenums and FRACs facilitated controlled air circulation and contamination control, ensuring the cleanroom performed at the needed classification level.
The impact of the project
Through the partnership, the customer was able to successfully re-purpose the existing building, adding a custom ceiling design that allowed AMHS and live loads to be met.
Throughout the 18-month project, the teams stayed in lockstep, avoiding significantly higher new building construction costs and timelines.
By repurposing an existing facility instead of constructing a new one, substantial capital was conserved.
The CleanTrak system was selected for its ability to accommodate custom plenum types
The efficiency was created through the custom ceiling design, which optimised airflow and AMHS integration, enhancing overall operational performance.
Costing $18m, the project underscored the value of strategic design and high-quality materials in cleanroom construction.
This project not only met stringent industry standards but also delivered outstanding financial and operational benefits.
Top image: A decommissioned building to retrofit a state-of-the-art cleanroom