1997 ACE AWARDS
PROJECT
Rockwell Semiconductor Systems – Fab 8-9
CATEGORY #9
Meeting the Challenge of a Difficult Job
Subcontractor
OWNER
Rockwell International
CONSTRUCTION MANAGER/GENERAL CONTRACTOR
DPR Construction
ARCHITECTS/ENGINEERS
Jacobs Sirrine Engineers
SUBMITTED BY:
Ludvik Electric Co.
MEGA-POWER FOR "MEGAFAB"
Rockwell Semiconductor Systems is a world leader in the manufacture of silicon semiconductor wafers for fax machines, modems, cellular phones, global positioning systems (GPS) receivers and other high-tech devices. To keep pace with growing demand, Rockwell invested in the construction of a huge $1.2 billion world-class fabrication plant in Colorado Springs adjacent to its exiting plant. The facility, known as "MegaFab", is designed to produce eight-inch 0.35- and 0.25- micron semiconductor wafers.
Ludvik was programmed into the mix as the design-assist electrical contractor on the fast-track Fab 8-9 portion of the project (future Fab 9 interior buildout is scheduled for completion in 1999). The scope and difficulty of the installation is the stuff ACE awards are made of.
A COMPLEX INSTALLATION
MegaFab is a four-level, 449,200 square-foot plant that will house Fab 8-9. Also included in the project was a 20,160 square-foot Central Utilities Building with a connecting tunnel to the Fab building. Fab 8 encompasses 275,000 square feet and includes a 54,000 square-foot Class I sub-micron clean room.
Ludvik’s responsibility included all normal, emergency and uninterruptable power, lighting, process and mechanical, equipment power, fire detection and early warning systems, public address, security, CCTV, telecom/data cable tray, freeze protection for process piping and roof drains, lightning protection, exterior lighting and snow melt systems for critical public areas.
Incoming electrical service is 12 million-volt amps at 34500 volts to a substation yard, with 15KV outdoor switchgear. The outdoor switchgear is 52 feet in length and weighs 85,500 pounds. It is the second largest switchgear ever built in one piece. Distribution within the facility is trough four 2500 KVA double-ended unit substations providing 480V, three-phase power. Emergency power is provided by two 1500KW diesel generators in outdoor walk-in housings. In addition, new 15KV feeders replaced service to existing buildings. To put it all in perspective, the facility will have enough electrical power to serve 2,000 homes. Mechanical equipment will provide airflow in Fab 8 at a rate of 3.5 million cfm. Chillers will deliver 2,700 tons of cooling capacity. Four million gallons of water will be purified weekly.
SOLUTIONS TO SPECIAL PROBLEMS
The fast track schedule, confined spaces and nature of the installation produced a variety of problems and obstacles for Ludvik throughout the project. Here are a few:
The most difficult problem was figuring out how to pull three 2-1/4-inch-diameter, 15KV, one million circular mill copper cables weighing 14 pounds per foot and totaling over seven tons of wire pull – with no splices by Owner request. Ludvik worked with Rome Cable to develop a unique solution. Since three wires could not be run flat, they were twisted into a single triplex configuration that fit the conduit. Instead of traditional pulling socks for each cable, a special "pulling eye" was fabricated and crimped onto the end of the triplexed cable. Hooking onto the eye then allowed the cable to be pulled through the longest conduit runs. Nothing like this had ever been done, considering the diameter, length and weight of the cable.
The enormous outdoor switchgear was manufactured to custom specifications in Southern California under close scrutiny by Ludvik personnel. Too wide for rail shipment, it had to be trucked to Colorado and delivered precisely on schedule – using the popular Garden of the Gods road in the middle of the busy tourist season! Mission accomplished.
To insure schedules were met, Ludvik personnel flew to factories in Iowa, Indiana, New York, Texas, Oregon, California and Wisconsin to coordinate manufacturing specifications and shipping schedules for a variety of specialized, innovative equipment and materials – an effort that paid off with quality materials and on-time deliveries.
Careful coordination with the Owner, the General Contractor and other trades enabled Ludvik to develop precise schedules and get pre-approval on certain activities which, in turn, allowed execution without the usual "gowning" for clean room installation – a measure that saved time on the electrical work and helped keep the project on schedule.
Manpower needs were met by utilizing a 10-hour work shift six days per week at the start of the project. During the peak work period, two 10-hour shifts comprising approximately 100 Ludvik workers were scheduled six days per week.
SAFETY CHALLENGES
There was no doubt about the importance of safety for Ludvik on this project from the start.
All employees received drug testing and an eight-hour safety orientation on policies and procedures, including fall protection, lift operation and other important safety issues. A degreed on-site safety professional oversaw safety compliance.
Work and emergency procedures had to be developed to deal with the project’s special conditions; hazardous materials, working in confined spaces such as 30-foot deep manholes and congested utility vaults, handling large conductor wires, tunnel evacuation and others. Four radios with separate channels for each work area were purchased to insure effective, timely communications.
In one area, the HEPA filter system incorporated 182 4’ x 6’ openings in the floor, over which Ludvik workers had to install conduit, bus duct and lighting. To insure safety, 182 special removable metal pan plates were made to cover the holes. Workers were able to drive lifts onto the plates to access work areas high above the floor.
With 100,000 hours expended in eight months on the project, Ludvik is happy to report there was no lost time due to accident. Seven minor accidents resulting in a payout of only $2,500 on the $11.3 million electrical contract is an outstanding achievement. In recognition of this excellent safety record, the Rockwell/DPR Safety Team presented 23 Ludvik foremen and personnel with special safety awards – the only subcontractor to receive such recognition.