Rockford served as design-builder for a highly complex retrofit, a coordinated renovation of active dry room environments within a live manufacturing facility. Facing shifting scopes and tight fab-in milestones, our team executed a phased, detail-driven approach that seamlessly integrated new infrastructure without disrupting production or sample timelines.
Phased Design and Construction Sequencing
To accommodate evolving fab-in schedules, Rockford implemented a phased design and construction sequencing strategy. This approach provided flexibility while ensuring the project remained on track.
- More than 50 formal design revisions were submitted during construction
- Each revision was integrated without missing a single fab-in milestone
- Sequencing plans were aligned with equipment delivery timelines
Collaborative, Customized Design Process
From the outset, Rockford partnered with internal stakeholder groups, including Electrode, NND, Assembly, Formation and FA teams, to fully understand utility and equipment requirements. This close collaboration enabled us to:
- Identify and resolve utility constraints early
- Adapt to site conditions based on real-time input
- Coordinate routing and spatial needs across active zones
Logistics and Environmental Controls
Operating inside a live dry room required heightened logistics and cleanliness protocols. Rockford developed tailored routing and containment measures to maintain clear separation between production and construction activities.
- Defined and protected fab-in access routes
- Temporary barriers installed to control dust and debris
- Monitored dust particulates in real time
- Implemented Rockford’s enhanced quality control protocol
Quality Control
Maintaining plenum cleanliness was critical to dry room performance. Rockford established a documented inspection and cleaning process, including a standard operating procedure designed to ensure long-term compliance.
- Routine plenum inspections with photo documentation
- SOP to safeguard air quality standards
- Ongoing condition tracking across all phases of construction
Utility Shutdowns and System Turnovers
Rockford coordinated more than 90 successful utility shutdowns to perform utility tie-ins, including two plant-wide shutdowns, without any disruption to production or sample output. This effort required rigorous planning and seamless execution.
- Comprehensive utility plans with risk assessments
- Daily coordination with facilities and engineering teams
- Installation and commissioning of three new 5,000 CFM compressors
- Tie-ins completed during active operations and testing
Building for Resilience
This project highlights Rockford’s ability to deliver precision-driven renovations in highly controlled environments. By combining phased planning, proactive collaboration and disciplined quality controls, we enabled uninterrupted operations while positioning the facility for future growth and innovation.
