Background

Client: Clas-SiC
Relationship with Client: This was a new client for AED, embarking on an ambitious venture to create a semiconductor fabrication facility. The client, Clas-SiC, was led by Carl Johnson, an experienced figure in the industry, and their mission was to manufacture state-of-the-art compound semiconductors. This project revolved around the need to create compound semiconductors on a silicon carbide (SiC) substrate, which allows for high-temperature tolerance, making it suitable for extreme environments such as missile systems.

The Problem: The client had already procured an existing building, however this building was not initially designed to meet the demands of a semiconductor fabrication facility. The challenge for AED was to design the facility’s cleanroom and associated systems to fit within the constraints of the existing building’s structure, while ensuring that all functional and operational requirements were met.

Project Summary

AED was responsible for designing the cleanroom, mechanical electrical process systems and all equipment hook up for the project. We had to create a functional space that adhered to the strict specifications required for semiconductor fabrication, including ISO 5, ISO 6, and ISO 7 cleanroom classifications. The cleanrooms were designed to accommodate various semiconductor processes such as photolithography, dry and wet etching, chemical vapor deposition (CVD), diffusion, implant, back-end prep and testing.

One of the primary challenges was adapting the design to fit within the confines of an already procured building that was not originally fit for purpose. This involved multiple iterations of floor layouts to ensure the equipment could be effectively accommodated while maintaining functionality and workflow. We meticulously planned the room designs, focusing on making the best use of the available space to meet the client’s technical requirements. Despite the limitations posed by the building, AED’s team developed creative solutions to ensure the cleanrooms would operate as required.

The project required precise coordination to manage the layout within a restricted building footprint. Had the design been done from scratch, we would have chosen a different building structure; however, the challenge was to retrofit the facility to meet the needs of SiC semiconductor production. The integration of multiple services and plant rooms within the limited space was a significant task, and ensuring the precision of floor plate designs was critical to the project’s success.

Key Achievements / Outcomes

Final Outcome:
AED successfully delivered the project, adapting the design to the constraints of the existing building while ensuring all technical specifications were met. Based on the success of the original cleanroom design, AED was also awarded the hook-up design for the facility’s fit-out. Our work on the project spanned RIBA stages 3 through 5, covering design, planning, and execution.

Client Feedback:
The client was highly satisfied with the outcome, awarding AED further contracts, including a possible extension to the facility. The client also recommended AED to other businesses, leading to new partnerships in Mumbai and other international locations. Additionally, Clas-SiC’s senior management recommended AED for our Cardiff University TRH project.