Aspen Aerogels Advanced Thermal Barrier Center
Marlborough, Massachusetts.
BEST PROJECT
Sent by: Ci Design Inc.
Owner: Aspen Aerogels Inc. | McCord Development Inc.
Main design company: Ci Design Inc.
General contractor: BW Kennedy & Co.
Civil Engineer: Highpoint Engineering
Geotechnical engineer: Terracon
Structural Engineer: Engineering Summit
The transformation of a long-vacant commercial building into a 59,000 square meter industrial manufacturing facility using state-of-the-art technology and materials required elaborate HVAC and electrical systems to support interior pressurization, a dense design of equipment and additional operational redundancy.
The design, formulated by the owner and contractor to optimize process flow, implemented selective equipment pads and slab replacements while also strategically locating mechanical equipment on the floor and ceiling to maximize interior space. Upgrades to electrical and gas services were built into the design to support highly specialized manufacturing operations.
Photo courtesy of Ci Design Inc.
The construction team says it went to work prepared for the unexpected problems that often accompany building renovations. In addition to site-specific safety plans, the contractor developed an overall silica safety program to complement the demolition subcontractor’s own safety measures, minimizing hazards during the removal of old floors, walls and concrete.
A safety clearance prior to the start of this work re-engaged workers in these programs, ensuring that all safety measures were in place. Likewise, a custom protocol guided all pipe pressure testing processes, providing an additional measure of safety for plumbing and sprinkler system workers. With these efforts, there were 45,000 hours of work with no lost time accidents or recordable incidents.
Photo courtesy of Ci Design Inc.
Designed to support the development of more reliable batteries for electric vehicles and energy storage systems, the facility features a rapid prototyping area and an advanced applications laboratory. Support spaces include a reception centre, cafeteria, meeting spaces, a customer engagement centre, offices and a large meeting room.
The facility was designed with sustainability in mind. In addition to the reuse of an existing building rather than an energy- and resource-intensive new construction effort, the project features a variety of finishes including low-VOC paint and recycled products and charging stations of electric vehicles.
Photo courtesy of Ci Design Inc.
The project was completed on schedule despite the owner’s added scope during construction, which included a new exterior dust collection system with an acoustic curtain wall, brand signage and various MEP alterations to align with the changes of process and equipment. With easy access to metropolitan Boston, the revitalized building will support the owner’s manufacturing goals and enable collaboration with industry partners, academia and customers, according to the filing.
