Finishout of 60,000 sq. ft. of research and development lab space on AMD's Lone Star campus. AMD's fast schedule was driven by their need to consolidate their operations to increase company efficiency. All construction took place in an occupied testing facility and there was no unscheduled downtime.
The R&D consolidation project brought many separate work groups together into a single open work area. Each of these groups has different equipment with different MEP requirements, different schedules, and different overall project needs. To help each user group visualize the layout of the new space and get their feedback on changes prior to installing work, DPR walked each through a mock-up of the space. Before laying out floors and installing equipment as it was shown on the plans, DPR ran everything through the end-users first. Each was shown – through mockups, sketches, blueprints – what their space would ‘look' like to help them visualize what they needed. Most of the silicon chip scientists moving in to the facility had never built a lab before and found this exercise helpful to pinpoint exactly what they would need.
The fast schedule left no time for shop drawing approvals or prefabrication. On mechanical and electrical-heavy projects like this, time is typically spent early on to review submittals with subcontractor teams, receive their approvals, and prefabricate much of the work. Because of the fast pace of this project, there was no time to review shop drawings or prefabricate MEP systems. Everything had to be approved, built, and installed on site and on the fly.
DPR supervised and coordinated the work on site as it was installed. Field engineers from the mechanical and electrical teams worked on site with DPR to hand sketch single sections of work. The sketches were emailed to engineers for approval, then fabricated and installed. DPR's superintendent coordinated the work of the teams to ensure the work – performed under raised floor and in the same space – continued efficiently without workers getting in each other's way.
Part of DPR's scope of work was to oversee the decommissioning, moving, and reinstallation of more than 150 different kinds of microchip research and testing tools. Each tool move involved the tool operator, riggers, movers, mechanical subs, electrical subs, and DPR. Each tool also had different requirements for downtime, MEP systems, and start-up, and a constantly changing schedule for when it could be moved, based on current production schedules.
DPR took a hands-on, tool-by-tool approach to supervising the tool moves. A mechanical/electrical coordinator was stationed at each end of the move to monitor the shutdown and startup. The superintendent at the project site coordinated installation subcontractors, making sure each parties was there when needed and that work was performed in the right order. For example, electrical connections must be made before compressed air, followed by process water. This process was repeated as tools were ready to be moved over the course of four months.
After project was finished, DPR had to take it all offline to install 120 zone valves in less than 48 hours at the request of the owner. These new process cold water zone valves were added to allow the owner to isolate smaller sections of the system for maintenance work, so all tools don't have to be shut down for one repair.