Messer

RPA Engineering provided full-service engineering and design for a new greenfield industrial gas and specialty chemical manufacturing facility supporting the production of raw materials for the semiconductor industry. The project included integrated structural, mechanical, electrical, plumbing, and fire protection engineering services and was master planned to support multiple future phases of development. The facility was designed to safely accommodate hazardous manufacturing operations while enabling long-term scalability and efficient site expansion.

Challenge

Phase 1 construction included a multi-use manufacturing building with mixed B-Business and H2/H3-High Hazard occupancies, introducing complex life-safety, structural, and HVAC challenges. In addition, the facility needed to support hazardous chemical storage, tanker loading and unloading operations, and future process expansion.

Engineering Approach

RPA Engineering implemented a holistic, master-planned approach to site and building infrastructure, ensuring that all systems installed during Phase 1 could support future phases with minimal disruption. Close coordination across all disciplines enabled safe integration of hazardous process areas, utilities, and support spaces. Design decisions emphasized safety, redundancy, code compliance, and constructability while anticipating future production growth.

Highlights

• Master-Planned Greenfield Development: The site was planned for multiple phases, including manufacturing space, outdoor chemical storage areas, and an office building, with utility and infrastructure systems sized to accommodate full build-out.
• Utility Infrastructure & Distribution: Incoming electrical power, water, and natural gas services were sized for all future phases, with sitewide distribution networks extended to planned future building locations.
• Hazardous Occupancy Design: Phase 1 included a manufacturing building classified as a combination B-Business and H2/H3-High Hazard occupancy, requiring careful coordination of life-safety, fire protection, and building systems.
• Structural Engineering: Structural design addressed deflagration risk in process areas and included foundations for exterior process equipment, tank farms, and hazardous material tanker loading and unloading zones, complete with secondary containment.
• Advanced HVAC Strategies: HVAC systems utilized dynamic supply and exhaust control strategies to support exhausted enclosures and gas cabinets, maintaining code-required face velocities while optimizing airflow for energy efficiency.
• Integrated Fire Protection & Life Safety: Fire protection systems were designed to support hazardous material handling, storage, and processing in compliance with applicable codes and standards.

Outcome and Impact

The completed Phase 1 design delivered a safe, scalable, and high-performance industrial manufacturing facility tailored to the demanding requirements of the semiconductor supply chain. By master planning utilities and infrastructure from the outset, RPA Engineering enabled seamless future expansion while minimizing long-term capital and operational impacts.