CLEAN ROOM EXPANSION 25K ISO 4
Beaverton, Ore.
BEST PROJECT, Award of Merit
Sent by: MWH Constructors Inc.
OWNER: Analog Devices Inc. (ADI)
LEADING DESIGN COMPANY: Corbin Consulting Engineers
GENERAL CONTRACTOR: MWH Constructors Inc.
CIVIL/STRUCTURAL ENGINEERING: Mackenzie Inc.
MEP ENGINEERING: Corbin Consulting Engineers
ARCHITECT: Advanced Technology Group (ATG)
SUBCONTRACTORS: Pence/Kelly Concrete LLC; Electric EC; Envision Controls Engineering; Streimer Sheet Metal Works Inc.; Mechanical Apollo; Mechanical Ocean Park
As part of a comprehensive multi-phase $1 billion expansion of Analog Devices’ semiconductor factory to improve its manufacturing capabilities, this $115 million project adds 25,000 square feet of cleanroom capacity, bringing total customer manufacturing space up to 118,000 square feet.
The cleanroom minimizes particulate matter such as dust, microbes, aerosol particles and chemical vapors to safeguard active manufacturing at the highest level.
The scope of work required the conversion of a former warehouse space, the placement of a new concrete slab and the construction of a mezzanine above the planned manufacturing area to support the units of recirculation air treatment, secondary production tooling equipment and service connections for production equipment on both levels.
Photo by Alfonson Diaz/MWH Constructors
Because the original facility was built in 1980 and was not ready to receive tools and equipment, the owner issued $33 million in early release packages to prepare the site.
With an active manufacturing space directly above the construction area, the project team implemented advanced measures such as temporary structural supports and soundproofing materials to avoid disruptions in both areas. Crews monitored structural stability, maintained life safety systems and protected the existing manufacturing space.
During design, feedback from the construction team was crucial in identifying risks and developing mitigation strategies, allowing work to be sequenced without unnecessary stoppages. When stops were needed, the team planned for months to create a detailed firmware. Hundreds of tasks were planned in 15-minute increments over 12- and 36-hour periods to allow rapid assembly, efficient installation of components, and minimal disruption. The project team also had to complete the cleanroom in just 12 months to accommodate a production tooling installation schedule.
Photo by Alfonson Diaz/MWH Constructors
To relocate existing utilities to accommodate the new project, the team mapped them all before developing a phased relocation plan that would minimize downtime and maintain operational continuity. New permanent systems were built to divert utilities, ensuring uninterrupted service. Then, after the links were completed, the old systems were removed.
During nearly 300,000 hours of work, the project team recorded an OSHA recordable incident rate of 1.3 and had zero lost time accidents. With project-specific safety programs in place, the team conducted in-depth reviews of the work plan weeks before any scheduled work to identify and mitigate potential hazards in advance. Daily safety incident prevention plans were developed for each activity and required thorough review and sign-off by the contractor’s and client’s safety department.
Extensive pre-task planning and workspace preparation also protected some critical areas. When crews had to work near unprotected hazardous piping systems, engineered controls were used, such as wrapping hazardous piping with hard barriers, wrapping in Visqueen plastic, and using drip pans to detect potential chemical leaks. The emergency switches of the equipment were also protected.
Delivered in July 2023, the new cleanroom has twice the original capacity and received ISO-4 certification a month ahead of schedule, just six months after the loft structure was completed. The project was completed at $3.5 million under the original GMP budget.
