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A pioneering battery manufacturer known for its high-density silicon-anode batteries is embarking on an ambitious expansion project. The company is converting a former Kmart distribution center into a state-of-the-art production plant. This move represents a significant leap from R&D to pilot manufacturing, to scaling up the production of their cutting-edge batteries used in phones, drones, military applications, and electric vertical takeoff and landing (EVTL) vehicles.

SSOE Group, with its recognized architectural and engineering design expertise in the battery manufacturing market, has partnered with Turner Construction to develop and construct the 775,000 SF facility, which is part of a more extensive 1.2 million SF multi-tenant complex. Phase 1 is engineered to have a production capacity of 500 megawatt-hours of battery power once in production.

Turner took the helm with site selection, evaluating potential sites across the U.S. Ultimately, a site in the west was selected offering an optimal climate, suitable humidity levels, and a robust utility infrastructure, complete with existing substations and the possibility for future expansions.

A rezoning effort was necessary to transition from a warehouse-only designation to one that includes manufacturing capabilities. SSOE and Turner provided expert support to a subsequent community engagement campaign, which was launched to dispel misconceptions and provide transparent information about the facility’s operations and processes. Despite facing initial resistance and a legal challenge
against the city, the rezoning efforts were successful, allowing the project to move forward.

Addressing the challenges presented by the brownfield site, SSOE’s team had to overcome layout limitations, which led to the design of an additional structure and modifications to the ceilings to create a suitable cleanroom environment. Moreover, relocating the process line from China to the U.S. required a detailed plan to comply with the diverse standards and regulations concerning electrical systems, utilities,
and piping, ensuring a seamless transition.

This company’s commitment to innovation and overcoming challenges, while harnessing the advantages of the environment and topography, position them to help transform the battery industry with its high-quality, dense power solutions.

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Looking to maximize utilized space on an already crowded campus, a major semiconductor manufacturer asked SSOE to design a new fab on a plot originally planned as a loading dock. SSOE designed the 150,000 SF facility to support 50,000 SF of cleanroom manufacturing space with minimum impact to adjacent fabs during construction and operation.

This project presented several challenges which were resolved with creative design solutions:

Flexibility for Next-Gen Fab Equipment
The client requested maximum flexibility to support current and next-generation chip manufacturing tools. This impacted the structural and vibration design of the building, as well as, the routing of process material and waste removal feeds within the structure to support flexible tool layouts from day one.

No Support Buildings
The team was asked to maximize production space and find alternatives to using dedicated support buildings, like a Central Utility Building (CUB) or bulk gas yard. The client and design team collaborated on a utility gap analysis to determine capacity shortfalls. Upgrades were made to existing systems that were required to support the new manufacturing space. As a result, the team designed and implemented basebuild-style upgrades to several systems on adjacent fab infrastructure to support the new fab.

Meeting Egress Code Requirements
With barely the minimum seismic gap between the new fab and existing structures, difficulties in meeting code requirements for egress routing became a constraint for the project. A deep knowledge of the applicable regulations, combined with strong AHJ coordination, allowed SSOE to develop and implement a safe and code-compliant solution.

Utility and Waste Routing
In addition to feeding the new fab from upgraded, existing utilities serving an adjacent fab, some utilities needed under-slab routing, which required a custom sleeve to accommodate differential settlement between the two facility foundations. Likewise, process waste was routed through the subfab area of an adjacent building to reach existing tie-ins capable of supporting the flows to existing collection points for on-site treatment and off-site removal of waste streams.

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SSOE was selected to act as the Owner’s Representative for this long-time food client on an important tomato sorting and processing project. Working closely with EC Nelson, the project’s Design-Build mechanical contractor, along with the electrical and integration contractors, SSOE provided design quality assurance and managed all aspects of the project on behalf of the client. The project was completed on schedule, in time for the seasonal arrival of tomatoes. The new electronic system sorts unpeeled tomatoes by quality and color, sending a larger percentage of high-quality tomatoes to the process lines making high-end diced tomato products, while directing the lesser-quality tomatoes to the evaporators to be made into tomato paste. The new process handles 280 tons of tomatoes per hour.

As the Owner’s Representative, we managed a multitude of moving pieces (designer, contractor, equipment manufacturers, purchasing team, project controls team) that needed to align at just the right times for successful project execution. SSOE also managed the master schedule, which included the engineering packages release timing, equipment ordering, the completion of programming, equipment testing, safety checks, and performance validations. Project team meetings were held weekly along with multiple meetings throughout the week to make sure project milestones were on track, and project status reports were delivered directly to the client’s upper management team. Additionally, we worked closely with Procurement to develop and process requisitions for purchase orders to support construction tasks as needed, while handling all administrative project-related tasks.

Key to the success of this project was our ability to be adaptable as we faced project challenges outside our control. Adjustments made included compressing the schedule when needed and sometimes having crews on-site around the clock. We utilized a combination of our Owner’s Representative and added an additional SSOE resource to shoulder the on-site night shift Construction Manager role, which ultimately reduced the schedule by a week and a half.

In March 2020, restrictions were implemented due to the world-wide Covid-19 pandemic, adding unforeseen project complications. At this time, we were tasked with providing a safe, Covid-free working environment, monitoring the ability of the client-ordered European equipment to be delivered to the U.S., and developing a solution to get key project staff located around the U.S. to the client’s site when needed. Solutions included the development of on-site safety protocols, which included mask wearing, taking temperatures, and completing health questionnaires. Most importantly, the client dedicated a several company jets to move critical resources to and from the site, including the Owner’s Representative and other key personnel. This helped ensure the project was completed in time for the July 1st arrival of tomatoes from the local farmers.

To meet the client’s deadline while completing the project safely, the roof was installed at nighttime during off-shift hours. SSOE’s on-site Owner’s Representative pulled double shifts until another SSOE resource could be brought on-site. This allowed the project to complete on time, saving the client $3,198,000.00 in production cost if all work had been limited to one shift.

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SSOE’s design of vehicle and powertrain manufacturing facilities returned more than the total fee in construction savings when compared to the competition’s design for the same facility.

Toyota has utilized SSOE as their trusted A/E partner of choice since 1999. SSOE’s structural department has consistently designed facilities for Toyota that could be constructed for less than any of their competition in the market place, regularly designing much closer to the actual service factor. SSOE consistently delivers on schedule for Toyota, and the number of errors and omissions experiences is much lower than what they had seen with their previous engineering services providers.

With these factors in mind, it was an easy decision for Toyota to select SSOE to provide the design to double the size of their automobile manufacturing plant in Princeton, Indiana and for their greenfield facilities in San Antonio, Texas and Tupelo, Mississippi.

In Indiana, having gained an understanding of Toyota’s goals and needs from previous projects in France, SSOE provided architectural / engineering services for an addition to the existing factory space to double the assembly plant.

In Texas, SSOE provided the facility design for a greenfield truck assembly plant on a 2,000-acre site that included suppliers. SSOE also provided on-site engineering staff to Toyota’s Owner’s Representative Office (ORO) to support the construction efforts and coordinate the design documents during construction phases.

In Mississippi, SSOE performed the master planning and design of the plant, as well as provided on-site engineering staff to Toyota’s Owner’s Representative Office (ORO) to support the construction efforts and coordinate the design documents during construction phases.

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SSOE was able to identify and suggest a 1/3 reduction in overall equipment costs for Phase II— translating to nearly $1.5 million in savings for the client.

To meet growing demand, a well-known electric vehicle manufacturer formed a strategic partnership with a leading battery manufacturer to construct a factory to manufacture electric motors and battery packs. The facility is being built in two phases, with the second phase involving the installation of additional battery production lines and associated utility system upgrades. SSOE was selected to provide engineering and design services for the second phase.

This project was uniquely challenging. Merging the battery manufacturing client’s improved technology with the vehicle manufacturer’s ongoing production capacity increase in one shared facility created a need for simultaneous site and equipment upgrades. SSOE’s cross-functional team assisted with planning all aspects of the expansion, virtually eliminating the risk of design gaps. Using this cross-functional team dramatically improved the holistic design and minimized issues in the field.

SSOE provided support for the following critical functions:

  • Utility Systems. Our team assessed system capacities, including compressed air, cooling water, dry room design alternatives, and production environment baselining. Once we understood these systems, we were able to determine which needed additions and/or modifications. Our focus then turned to the details around battery manufacturing. Beginning with raw material flow analysis, we then followed with space planning to ensure the production equipment would fit. The team confirmed that proper maintenance and utility spaces were incorporated into the design and that the equipment was in working order. SSOE also provided regeneration options for site HVAC systems and all water and water cooling systems.
  • Safety. With safety at the forefront of all projects we execute, our team provided chemical process analysis and confirmed proper permitting and certification for chemical usage in various manufacturing steps. We also ensured overhead clearances, aligned beam attachments to catwalks, and confirmed proper electrical, egress, and operational clearances. SSOE’s design assured both people and equipment could move safely throughout the facility.
  • Site Stability. SSOE’s structural team inspected site supports and analyzed how the equipment operated to ensure proper anchoring for safety and successful long-term production. Our team recognized that previous equipment installations had been insufficiently anchored, which caused damage to the slabs and cracked the foundation. We were able to mitigate these issues and provided suggestions for improvement. Additionally, SSOE partnered with both clients at the project onset to align on the optimal project approach. Through close collaboration during the construction and procurement stage and supporting the trade bid process, SSOE helped reduce overall equipment cost by about one-third of the project budget, translating to about $1.5 million in savings. With additional battery production lines slated for installation in the near future, SSOE’s practices will be replicated, with better documentation and a strong basis of information to copy, which will result in future operational savings.
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Through innovative design concepts, benchmarking common practices, and scheduling, SSOE has saved the client more than $7.3 million to date.

Nimble and resourceful, SSOE quickly increased personnel for a critical tool installation design project when a semiconductor client accelerated release of a new technology. This project, part of an ongoing program for the client, included the installation of 250 tools over the course of a year.

Initially, the project required all design work to be performed in Oregon. However, due to the quick ramp up needed on this project, the client determined that design work could be completed remotely. SSOE quickly responded, engaging tool installation design teams in New Mexico and Arizona to support the Oregon team. In addition—for the first time in SSOE’s tool installation design program history—SSOE’s Mumbai, India, and Leon, Mexico, teams were engaged to provide critical support to meet project demands. Getting these international team members on board allowed for greater agility and flexibility on this project. In addition, it allows for a trained workforce to be available on short notice for burst capacity as well as subsequent easing off the project as workload diminishes. This approach keeps SSOE’s project budgets and schedules healthy and, in turn, enables our clients to get their products to market on-time to meet demand at a competitive price point.

In addition to providing a high level of service on this project, SSOE implemented a number of efficiencies that have saved the client more than $7.3 million to date. A utilization-based resource staffing model and a workshare agreement form, as well as innovative design concepts, have all contributed to these significant project savings.

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SSOE provided architectural and engineering design services for KORE Power’s greenfield battery cell production facility, KOREPlex. KORE Power, a U.S.-based developer of battery cell technology for the energy storage and electric transportation industries, collaborated with Yates Construction and SSOE as the Design / Build team. SSOE advanced the design package to 60% completion at which point the client halted further design and construction.

The KOREPlex design included automated cell assembly lines, automated material movement and handling, an automated packaging line, and a pandemic-ready design to allow for safe workspaces.

The facility’s many cleanrooms were designed to maintain very low humidity requirements throughout the space, some targeting a temperature / humidity set point within the -45°C dew point range. The design used dedicated desiccant chilled water dehumidification units to dry the air, while providing space-level cooling. The rooms also utilized recirculating air handling units to allow for HEPA-level filtration and overall cleanroom pressurization requirements.

The SSOE team drew upon our unique expertise in the battery manufacturing sector to develop the KOREPlex designs—combining our understanding of large-scale manufacturing facilities with a technical mastery of controlled environments and process engineering.

The KOREPlex facility was designed to support up to 14 gigawatt hours (GWh) of battery cell production, producing nearly 60 million battery cells annually. The new facility would have production capacity to provide power for 3.2 million homes per year.

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SSOE worked with Nikola Corporation, a leading designer and manufacturer of heavy-duty commercial battery-electric vehicles (BEV), fuel-cell electric vehicles (FCEV), and energy infrastructure solutions, as a design partner for their new manufacturing facility in Coolidge, Arizona.

Now complete, the zero-emissions facility has the capacity to produce Class 8 commercial semi-trucks. The facility features in-house offices, conference rooms, and support facilities which showcase Nikola technology and culture.

As part of the initial facility master planning, SSOE provided a conceptual site layout and arrangements for the envisioned facility, including block diagram floor plans. Our team presented a conceptual artistic rendering for the exterior facility design in its surroundings to provide a realistic representation of the proposed facility, drawing from examples of desired building aesthetics provided by Nikola.

The SSOE / Walbridge team helped the Phase 1 master plan vision into a reality by providing design and construction management services.

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A well known OEM forecast a significant increase in electric vehicle production. To meet the unprecedented demand this would create for lithium ion batteries, the automaker formed a strategic partnership with a leading battery manufacturer. Together, they aimed to construct a shared plant that would produce both electric motors and battery packs.

The facility is being built in phases, the first of which was made up of multiple sections of the plant totaling 6 million SF. The phase-one project was unique in that all facets of its design and implementation were led and executed by an internal team under the manufacturer’s authority—meaning the owner was also the designer, engineer, and construction manager. The team selected SSOE as a design partner for this phase with the flexibility to embody their out-of-the-box thinking and make their progressive goals a reality. SSOE provided key on-site and remote staff augmentation, in support of these critical functions:

  • Process Integration – assisted with design and specification for a portion of the initial process-related facility packages (including local DI water stations and local wastewater lift stations), engineering support for the process systems, and a significant amount of PIPE-FLO modeling for many plant utility systems.
  • Process Chemical – performed HAZOP, pipe supports, facility integration, and redesign of several bulk systems to meet updated needs or code requirements. Additionally, SSOE acted as a design and equipment specification “sanity check” for components on several of the small and bulk chemical handling systems.
  • Utilities – provided a significant portion of the Revit modeling for utility systems, as well as equipment layout in the utility support buildings.
  • Mechanical / HVAC – provided a substantial share of the Revit modeling and engineering support for the mechanical / HVAC systems for the facility.

The fluidity of design on this project created complications due to multiple sections of the facility being worked on interchangeably. SSOE’s engineers tackled these challenges by proactively solving problems, independently finding missing information, and piecing together details to achieve aggressive deliverables and goals that other A/E firms deemed impossible.

Ultimately, SSOE collaborated seamlessly with the manufacturer’s internal team. Drawing on industry expertise, the augmented staff was able to provide input on decisions that resulted in operational efficiencies, an improved layout, schedule compression, and more than $5 million in savings.

The facility will not only meet its lofty production goals, but also produce batteries for significantly less cost. Notably, it will be powered by renewable energy sources, with the goal of achieving net zero energy.

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SSOE has been performing design engineering for tool installation packages for MOK (Multiple of Kind) and FOK (First of Kind) tools for multiple functional areas of this world-leading semiconductor client’s development manufacturing facility. This project launched the client’s new business methodology of designing engineered packages from one location for projects around the world, with part of the team on the ground for design review and fieldwork and the remainder of the team in other U.S. locations. This enabled the client’s internal engineering design staff to exert more control over the design process for standardization throughout the entire corporation.

Because of our success, SSOE was able to be highly efficient, leveraging the skills of SSOE team members operating in multiple locations including Santa Clara, Oregon, New Mexico, and Arizona.

Schedule was a significant challenge for this program, as rapidly evolving technologies and developmental fine-tuning resulted in the needs changing throughout. SSOE’s flexibility and skill at managing scope change has been key to the success of this project—enabling the achievement of client productivity goals. In recognition of SSOE’s ability to keep pace while maintaining a high level of quality, the client consistently allocates additional scope above and beyond the standard tool installation design.

The team’s exceptional attention to detail extends to our cost management systems. Through lean management and continuous process improvements, SSOE continuously returns savings to the client. This culture and focus has given the client confidence in SSOE’s abilities, as evidenced in additional project awards.

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SSOE saved the client $7 million in installation costs by leveraging PPMOF and BIM.

A global semiconductor client had plans to fit out an empty manufacturing building with process tools for a new technology. They selected SSOE to design the build-out of the sub fab laterals because of our extensive BIM capabilities. SSOE led the work for the subfab process laterals—an extension of utilities that would facilitate process tool installation on the level above. The 1300 process laterals included chemicals, gases, waste, waters, exhaust, telecom, and life safety systems. The team facilitated an early construction start date and saved the client money by leveraging several unique work approaches:

PPMOF: Prefabrication, Preassembly, Modularization, and Off-site Fabrication

SSOE approached the design with the client’s goal of PPMOF in mind. This strategy allowed installation coordination to take place early, providing schedule and labor savings. The team designed the strut racks to be fabricated off-site, then lifted into position in modules. All water, gas, and waste lines were fabricated with valves off-site in the longest lengths possible to rig onto the rack.

BIM2Fab

SSOE team members transitioned BIM design models into construction models to aid in the execution of PPMOF and eliminate project waste by removing the need to create a construction model from scratch. The construction models were then used to produce fabrication (spool) drawings for the trade partner to fabricate off-site. The team saved additional time by eliminating the typical contractor redline process used to develop record drawings. Since the model was used for fabrication there were no deviations from design. Such tight alignment resulted in the achievement of zero-redline designs due in part to SSOE opening up our office to enable the trade partners to co-locate with SSOE during the project.

Kanban

Kanban, a scheduling system for lean manufacturing and “just-in-time manufacturing,” was used to coordinate design efforts and streamline communication. This was the team’s first time using this software across companies—between SSOE and the trade contractors. It provided visibility of hand-offs between each company resulting in zero lost time and minimal email communication.

International Workshare

By collaborating with counterparts in India to achieve day and night design effort, the team was able to ramp up production to help meet the aggressive schedule set for this project. The use of Kanban for hand-offs between the two teams was crucial in meeting many of the project milestones. This method provided an estimated 50% increase in productivity.

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In a multi-billion dollar industry where companies feel pressure to continually innovate and increase efficiency, semiconductor manufacturers cannot afford to have anything stop production in their fabrication facilities. This global semiconductor client discovered that the cleanroom in their aging mask operations facility was at risk of going out of compliance due to the state of the mechanical systems. The client chose SSOE, through our Joint Venture Design / Build partnership with JE Dunn, to embark on a nearly 2-year, $150 million project to modernize the facility, bringing it up to specification and into compliance with current standards for code, reliability, and safety.

Upgrading of the facility’s mechanical and process systems was a large undertaking. The work included: 

Hazardous chemical storage space. SSOE addressed the need by expanding the chemical storage space and necessary support systems including exhaust fans and scrubbers, and safety treatment systems for chemical storage areas.

Acid waste neutralization system. SSOE upgraded this system by adding a caustic storage and distribution system and reaction tank modifications.

Additional mechanical and process system upgrades. These included chilled water, heating water, system cross-ties to provide redundancy, process vacuum, house vacuum, and process chilled water supplying the process tools in the fab.

BIM2Fab. SSOE performed detailing of the heating water and chilled water piping to produce fabrication drawings of the piping for the system crossties.

Clean-up. To create adequate space for all new systems, the team demolished and removed obsolete equipment.

A small team on the ground at the client’s facility received support from a remote design team residing in multiple SSOE offices. The project team made extensive use of BIM and Point Cloud software, eliminating the need to locate an entire team on the client’s site. This resulted in significant project savings and allowed the team to make the most of the resources available to them.

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Facing ever-increasing industrywide pressure to reduce cost and time to market, a world-leading semiconductor manufacturer needed to increase efficiencies on its 300-acre technology development campus. This project involved the design and construction of a 43,000 SF structure, known as a “cleanlink,” to connect the chip maker’s primary research facilities—allowing for the seamless integration of manufacturing.

Prior to this structure’s completion, cleanroom staff had been forced to use complex and time-consuming measures in order to fully utilize the separate fab buildings. With the cleanlink in place, wafers can now move to the other fabs on campus without leaving a clean environment and risking damage to the product.

Moving wafers within the link and fabs is accomplished by an Automated Material Handling System (AMHS). More than 2.5 miles of overhead track connect the AMHS wafer conveyance systems of multiple buildings, allowing for direct tool-to-tool WIP movement without human intervention.

The cleanlink consists of three structures:

A Transition Building. A two-story Transition Building with H5 occupancy was designed to enable the AMHS to overcome the elevation difference between two of the buildings. It contains multiple catwalks and interstitial levels, providing access for maintenance for both the transition devices and the AMHS. Wafers are moved both horizontally and vertically within this space.

An AMHS Link. The AMHS Link was designed to accommodate pedestrian traffic, but its primary function is to support and enclose the AMHS track system. An interstitial level provides access and maintenance points for servicing the AMHS.

A reconstructed utility bridge and pedestrian walkway. SSOE and JE Dunn removed and reconstructed 80% of an existing pedestrian walkway to more effectively handle the upgraded AMHS system and to create a more efficient walkway used by people every day.

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Following the client’s success in a high-volume manufacturing facility using a new design methodology—providing design engineering for tool installation packages from one location for projects around the world—SSOE was requested to mobilize for a new project in a second high-volume manufacturing facility. SSOE augmented a small team of local staff in Arizona with design staff in Oregon, New Mexico, and Ohio to perform MOK (Multiple of Kind) tool installation designs for the most complex functional area of this world-leading semiconductor client’s high-volume manufacturing facility.

Two A/E firms were already on-site performing design work locally but were unable to meet the steep demand curve of this new technology transfer project. Integrating into the site where existing BKMs and stakeholder expectations differed significantly from contracted deliverables proved a significant challenge. SSOE was recognized for leadership in promoting the new program to client stakeholders and guiding other A/E firms on the program parameters including code compliance issues, project reporting, and quality program implementation.

SSOE started 79 and completed 31 tool design packages in its first quarter on-site and closed a backlog of highly complex tool conversion designs within 8 weeks. While mobilizing from 0 to 28 staff across 4 sites and with significant schedule and stakeholder availability issues, SSOE maintained a 100% performance against schedule rate and a 98% positive quality scorecard rate.

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SSOE completed a complex programming and schematic design effort for an approximately 1,100,000 SF, seven-story multipurpose building that serves as a model for workplaces of the future.

The building contains a 2.6 MW data center, two floors of class 10,000 high-tech cleanroom manufacturing and chip testing space, with five floors of office, cafe, and fitness center spaces to accommodate approximately 3,800 employees. Linked connections to neighboring buildings were created to provide passage for employees, utilities, and automated material handling systems. A pedestrian sky bridge to the parking garage was designed to accommodate a direct, convenient connection without impacting the existing wetlands. The project, utilizing a high-performance envelope, daylighting strategies, and high-efficiency mechanical systems, met the criteria for LEED Silver certification.

The office levels were organized into neighborhoods consisting of workstation groups, collaboration rooms, and community zones. These were combined with support spaces based on a formula for connectivity and an interactive office environment. Small and large community zones are located throughout the floor at strategic points where employees can work, meet informally, or relax as a community.

The objective was to create a design aesthetic to complement the existing campus architecture. Throughout the design process, this goal was elevated to create a distinctive architectural look that reflects the values of our client and today’s workers.

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Decrease natural gas use by 30 billion BTUs a year; saved 19 million gallons of water during first year; project savings of more than $280,000.

When a long-time food manufacturing client wanted to assess opportunities for energy savings at one of its facilities, SSOE had the expertise to both evaluate existing plants and systems and also recommend and implement process and mechanical improvements to achieve cost and energy savings. By conducting an energy savings audit, including heat recovery potentials, SSOE helped identify areas for energy savings.

SSOE first reviewed heat recovery and other energy saving opportunities at the plant. Over a two-month period they conducted an FEL 1 study on three different projects where the client had initiated plans for energy conservation. SSOE determined whether or not the client’s projects were viable enough in terms of expected results and return on investment (ROI) to proceed in implementing. The results and SSOE’s recommendations were then provided to the client for further internal action.

SSOE’s energy audit proved to be successful, as it identified potential energy savings of over 70 billion BTUs per year (70 million cubic feet of natural gas per year). SSOE also reported more than $280,000 savings on the project.

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14% less energy use for long term savings. Environmental pilot for future facilities.

As part of the Army and Air Force’s initiative to construct all new buildings to green standards, the Army and Air Force Exchange Service (AAFES) made plans for a new, sustainable retail facility on the Randolph Air Force Base in Texas. The one stop, state-of-the-art facility, serving more than 50,000 active, reserve, and retired military personnel and their dependents, was one of the first AAFES facilities to pursue LEED Silver certification. It was also part of the USGBC’s pilot program to develop LEED guidelines for the retail industry. SSOE spearheaded the design of the facility with a with a food court, sales area, specialty vendors, onsite fuel stations, outdoor lifestyle areas, and a loading dock, while also leading LEED certification efforts.

SSOE designed a data / voice, fire alarm, and mass notification combination system for this 167,000 SF facility. As part of the data communication system, a wireless study was performed to determine the best placement of wireless internet antennas. The wireless system was designed to comply with the IEEE 802.11 wireless standard.

Using more than 20% recycled materials, the facility also features an energy management system to coordinate efficient lighting, heating, and air conditioning systems that reduce energy consumption and costs. A roofing membrane reflects 78% of sunlight minimizing energy use within the facility and water-efficient equipment reduces water consumption by 20%. A central cooling tower and chilled water system provide a high efficiency means to cool the complex. Using 14% less energy than a traditional similar facility, AAFES has used this environmental model as a pilot example of how to conduct future design and construction projects. Other distinctive aspects of the project include implementation of Anti-Terrorism Force Protection (ATFP) standards relative to siting considerations, building controls, and security systems.

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Within 36 hours, SSOE arranged and obtained aerial photography of an alternate project site.

In addition to designing this greenfield truck assembly plant, SSOE also provided site evaluation services for the 2,000 acre site. The project required a high level of confidentiality throughout the entire site evaluation process and SSOE worked with state and local economic development authorities to locate the potential properties for analysis.

Site services included evaluating topography, climatic conditions, severe weather potential, transportation, soils, hydrological, electric service, gas service, water service, wastewater treatment service, and rail service at various locations in multiple states in the central and South Central United States. SSOE evaluated project sites ranging from 1,800 acres to 2,300 acres. Site observation visits were performed on the preferred geographic locations. A site report was prepared along with supporting documentation for each site. To provide a ranking of each location, a summary matrix of critical attributes was presented to Toyota electronically for use by top management.

Utilizing 3D MicroStation design platform, SSOE electronically produced the architectural rendering for ground breaking announcements, press releases, and public relations purposes. Toyota also requested an additional site evaluation in a neighboring state and within 36 hours, a helicopter was dispatched and obtained digital video of the site fully annotated showing key site features.

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SSOE assembled a team specializing in cleanroom design and construction to engineer, design, and support construction of multiple basebuild systems including a cleanroom installation at a facility in Boise, Idaho. The client, a semiconductor and memory manufacturer, relied on our expertise to provide support for the projects under a fast-track schedule, while managing multiple onsite subcontractors as SSOE converted the building into a cleanroom facility.

After meeting with the client and performing an exhaustive investigation of the site, SSOE provided preliminary engineering and scope development services for the facility. The existing structure required a thorough structural analysis to ensure that it could support future equipment installations, which we provided under a tight deadline.

The structural scope included an exhaust stack support, utility racks, a bulk gas tank, and the cleanroom ceiling. Our process team created numerous systems including ultrapure and hot ultrapure water, solvent waste, chemical delivery systems, and bulk and specialty gasses. SSOE designed the cleanroom HVAC system for clean production space, and modified the existing HVAC system for the support areas.

In collaboration with the client, SSOE constructed the house VAC and OFA systems to meet the requirements of the upgraded facility as well as modifying the air handlers to change capacity as needed. The coordination of the bulk tank and chilled water systems required constant cross-discipline communication and careful schedule management. The utilities for tools and building services, and controls were also included in our scope. Understanding the client’s needs, we laid out the facility for future tool installations, and took care to include as much of the existing system as possible, while offering cost-effective recommendations for modifications and upgrades based on future need.

SSOE integrated the client’s existing project documentation procedures with our own, which allowed for swift responses to critical questions and submittals.

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This fast-track project was completed on time and on budget with documented SSOE generated savings of $12.8 million.

TPCO America, a manufacturer of high quality API Grade steel tube, sought to establish production facilities in South Texas in order to capitalize on the growing demand for steel tube generated by the oil and gas industry. As a subsidiary of Tianjin Pipe Corporation, China’s largest producer of seamless steel pipe, TPCO understood the importance of having American engineering and construction companies on board who are experts in designing and delivering integrated production facilities worldwide. SSOE and its construction partner, Yates Construction, were selected for their vast experience successfully delivering similar projects worldwide.

The design / build team of SSOE and Yates is responsible for the complete design of the pipe rolling / pipe finishing mill, with SSOE providing architectural, engineering, and design services for the plant, including facility and infrastructure design, facility and process utilities design, process integration, equipment installation, and construction support.

Working closely with Yates, SSOE is applying a concurrent design / build approach, which makes it possible for the team to deliver the 1.6 million SF facility on a compressed schedule. The pace of the project increases the importance of SSOE’s job to coordinate all aspects of the work with Yates.
The project site provided significant challenges, as a substantial amount of stabilization was required due to its sandy composition and the need for very stable foundation for processes. SSOE designed a piling network to stabilize the substructure and distribute the load to maintain alignment and functionality of manufacturing systems in the future. To maintain the project budget, SSOE worked with Yates to research and provide the most economical design and construction solutions for this site.

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Taking advantage of the local climate allowed SSOE to design an energy efficient facility, reducing energy costs.

In late 2012, SSOE Group merged with Evergreen EDC bringing significant synergies to both firms’ data center capabilities.

Digital Realty, a worldwide leader in data center solutions, selected SSOE to provide architectural and engineering services for its customer’s new 52,000 SF facility in Hillsboro, Oregon. The 4.5 MW data center was designed using modular and scalable design principles and includes four identical and independent server equipment room PODs, each approximately 4,600 SF and containing 120 cabinets. Two additional PODs have been included on the site master plan and can be added in the future. The modules are organized along a central service corridor, which provides access to the server, electrical, and battery rooms. The rooftop air handlers utilize air side economizers to provide “free cooling” to the data center for up to 10 months a year. Cool air is supplied to an overhead plenum that distributes the air to the server cabinet cold aisles. The cold aisles are architecturally isolated from the rest of the room (hot aisles) using modular wall components, which assures efficient air flow and eliminates the mixing of hot and cold, thus reducing overall energy costs.

The most significant challenge on this project proved to be fitting the building program requirements within a small, sloping site. By implementing a rapid prototyping design process, SSOE was able to quickly produce a wide range of building configurations and site master plans, allowing the owner the opportunity to provide timely input. The use of this design process was instrumental in keeping the project on schedule and ensuring the owner’s needs and expectations were met. In the final design, SSOE maximized the building footprint by wrapping the support spaces around the server room modules.

The result is a dual-corridor system, one for service and the other for client access, which meets the varying levels of security protocol required by the owner. The building was also orientated and formed to take full advantage of the overall depth of the site, while still maintaining a separate and secure entry for both on-site parking and service yard access. SSOE raised the finished floor elevation of the building in order to balance the cut and fill requirement on the site, and to eliminate off-site soil disposal.

SSOE’s design process, relationship, and familiarity with the local code jurisdiction were instrumental in meeting the aggressive project schedule. We worked cooperatively with Digital Realty to design a cost effective, energy efficient data center that met their current demands, while also maintaining flexibility to adapt to future growth.

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SSOE saved the client 1,000 man hours and helped to streamline activity in the plant.

When this food manufacturer built a pilot plant to develop a new method of making tomato products using a new evaporator system, they realized they were limited in the manpower they needed to master the process. With a need for additional on-site support, the food manufacturer wanted a partner that not only had expertise in design process, but had a fundamental understanding of the hands-on approach needed to learn the functionality of the system and to help ensure its success. With an alliance agreement in place, the client commissioned SSOE to manage the start-up process at the facility under a Master Service Agreement (MSA). Noted for its vast expertise in tomato-based products, SSOE’s experience runs the gamut from bulk ingredient receiving through USDA/FDA inspection, sorting, processing, filling, packaging, palletizing, and warehousing.

The pilot plant, built on an existing tomato processing site, used outdoor energy efficient evaporators that used less steam to process, at minimum, 5,000 pounds of tomato for concentrate and paste. In its role, SSOE was first charged with the oversight of day-to-day pilot plant operations, including running the process system, leading repairs, troubleshooting processing issues, as well as cleaning the system.

In its second year of on-site support, SSOE transitioned plant operations to the client’s team, training them and sharing the expertise acquired during the initial pilot plant phase. SSOE also offered input on implementing control measures and means for improving site processing. Ultimately, SSOE saved the client 1,000 man hours and helped to streamline activity in the plant.

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SSOE worked with TOK America to duplicate the design and installation of a mixing and blending tank at their Hillsboro, Oregon, location. With our history of efficient design and precise field verification, SSOE staff analyzed and mirrored the corresponding system, installing a new batch tank and transfer system in the existing building. After managing the construction effort, the facility drawings were updated with the new tank and its associated systems.

Later TOK America decided to add an additional tank. SSOE compiled six options for the new tank – from reusing a tank on-site to installing a brand new system, keeping in mind budget, time, and operational expenses. Through 3D modeling SSOE was able to illustrate how the tank would fit into the existing facility, and make swift changes in response to TOK’s needs. A structural frame was also engineered and fabricated to support the mixer sitting above the existing tank. SSOE then provided programming for the new mixed tank. Throughout the process, SSOE collaborated with TOK to analyze their needs and provide cost-effective solutions.

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SSOE was awarded a nationwide, five-year IDIQ contract for A/E services related to master planning for over 12 million SF of the EPA’s environmental and analytical laboratory and support facilities. This included coordination with EPA program and regional offices to incorporate their missions and strategic goals into specific master plans.

SSOE has completed the following tasks for the EPA:

Research Triangle Park (RTP), North Carolina
The RTP EPA Research and Administration Facility consists of approximately 1.4 million SF of laboratory, vivarium, office, and special use space.

SSOE has performed the following tasks at this site:

  • Facility master plan
  • Programming and planning to relocate the EPA Division now located off-site into the RTP facility
  • Energy reduction strategies
  • Evaluation of sustainability opportunities

Chapel Hill, North Carolina
SSOE completed an engineering study to provide recommendations for energy reduction strategies and HVAC improvements.

Narragansett, Rhode Island; Athens, Georgia; and Corvallis, Oregon
SSOE provided master planning services to address the renovation of the existing 40 year-old laboratory buildings, strategies to meet/exceed EPAct and EISA criteria, and a “green” strategy for restructuring the site.

Las Vegas, Nevada
SSOE developed a POR and Design Intent documents for a new two-story, 40,000 SF leased laboratory / office building. This building will house the offices and laboratories of the EPA’s Radiation and Indoor Environments National Laboratory currently located at the University of Las Vegas.

Houston, Texas
SSOE developed the POR for a new EPA Region 6 build-to-suit 10 acre campus, including a 90,000 SF laboratory building and support facilities.

Edison, New Jersey
SSOE developed a POR for a new 400,000 SF, state-of-the-art Environmental Science Center. The new facility consolidates the Edison EPA’s program into one building, replacing the aging, inadequate existing facilities.

Fort Meade, Maryland
SSOE completed a conceptual design for modifications of the EPA Environmental Science Center to allow for chemical warfare agents testing as requested by the Department of Homeland Security.

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Process developed had six month payback and increased the overall product yield by 10%, generating $2 million per year in extra production without an increase in feed stock quantities.

When the client acquired a rural site to take in municipal waste, railroad ties, and used tires, it sought SSOE’s process engineering expertise in transforming the brownfield site into an alternative energy facility. The client needed to ascertain if these elements could generate sellable chemicals and result in a commercially viable business. As one of the top ranked chemical plant and green industrial and manufacturing design firms, SSOE was uniquely qualified to tackle the complexities of front-end process design while planning a fully functioning, energy-efficient facility.

SSOE performed preliminary and detailed chemical process engineering involving putting the waste products through a plasma gasification system, producing syngas, and generating methanol and DiMethyl Ether with future capacity to produce mixed alcohols (butanol, ethanol). In developing the process, SSOE discovered a means of recovering hydrogen from the purge gas stream that increased the client’s overall product yield by 10% with a six-month payback. Overall, the plan generated $2 million per year in additional production without an increase in feed stock quantities.

SSOE performed process studies for capacity improvement and evaluations of alternative technologies, including alternative refrigerants. Its process engineering services included developing the process alternatives, process modeling once the Process Flow Diagram (PFD) was finalized, and identifying manufacturing solutions for all of the unit operations. It also provided input for environmental filings and responses to due diligence queries from the financing engineer.

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Reduced engineering schedule by 30%, saving GLE $60,000 a day.

Glacial Lakes Energy (GLE), a manufacturer of corn-based ethanol, underwent a capacity increase to more than double their existing capability. SSOE provided full engineering, design, procurement, fabrication, erection, and commissioning support. We coordinated with GLE, the contractor, and the process provider to successfully complete a fast-track, turnkey project which increased GLE’s existing ethanol production to 100 million gallons per year.

SSOE utilized staff in its Shanghai, China office to provide 24-hour project support, which reduced the engineering schedule by 30% and helped bring the facility to full production capacity in just 11 months. Also, as a result of the accelerated schedule, the client recognized a sizable profit. GLE saved $60,000 per day, which equaled approximately $1.8 million in profit per month.

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SSOE provided on-site assistance at the fist beta site unit which has prepared this company for additional installations and further enhancements to the turbine and balance of system design.

Wind Energy Corporation executed a multiphase project at two separate locations. SSOE provided design and application engineering services for a new vertical axis wind turbine. In the first phase of the retrofit project, SSOE optimized the design of the turbine unit, its structural supports, and power electronics integration. In addition, the project scope included the complete integration of the prototype vertical axis wind sail system. SSOE also provided inverter specification, electrical permit drawings, and controls system development.

As part of SSOE’s Value Promise, SSOE provided on-site assistance at the first beta site unit, which prepared this company for additional installations and further enhancements to the turbine and balance of system design.

For the second phase of the project, SSOE delivered product development support which required multidiscipline team coordination. This effort included control and transmission development, inverter specifications, and system integration for planned installations – executed by our electrical controls team. SSOE’s structural team provided specifications for tower mounting and building integration. By utilizing a planned installation project delivery method, SSOE delivered the project on schedule, which was based on timelines and critical milestones.

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