In 2019, a global leader in semiconductor manufacturing announced that it would make a further major investment at its manufacturing campus in Ireland, with the construction of 2 new semiconductor fabrication facilities, or “FABs”. With a total CAPEX value in excess of $7 billion USD, this truly is a mega-scale project.

Given the scale of the project and the project’s ambitious construction schedule, the end client and their construction partner, Exyte, embarked on an Off-Site-Manufacturing “OSM” strategy which would see 40% of the project built off site.

With a 30-year track record in delivering critical power equipment to the semiconductor industry and having demonstrated our extensive Modular capabilities during the competitive tender process, Anord Mardix were selected as the partner of choice for the Low Voltage Electrical Unit Sub-Stations, or “LV-USS” and E-Houses (Power Pods).

KEY FACTS

Client: Confidential, but our construction partner was Exyte Ltd.
Country: Ireland
Project Value: In excess of €55 million
Industry: Semi-conductor Manufacturing
Products:
  • 108 x Large MV-LV power transformers
  • 38 x 6300A LV switchboards
  • 1000M of 6300A Busbar Duct
  • 29 x Power Skids
  • 8 x Mega Power Pods

Timeframe: 2 years
Year: 2020/ 2021

PROJECT CHALLENEGE

  • Ambitious schedule
  • OSM challenge

There was a requirement for 9 of the Unit Substations to be housed in custom designed, Off-Site manufactured Power Pods. This was a separate ‘design and build’ contract awarded to Anord Mardix, which was successfully delivered despite the significant engineering challenges involved.

The Power Pods were manufactured at Anord Mardix Dundalk and delivered/installed by escorted convoy at night, due to their sheer size! Two of the Power Pods were installed on the roof of the main FAB building; each weighing in at 160 metric tons, and 24 meters long x 9 meters wide each!

  • Covid-19

The onset of Covid-19 in the spring of 2020 made construction and manufacturing slightly more difficult, with Anord Mardix and other partners on the project having to adhere to strict health and safety guidelines to keep all team members safe.

THE ANORD MARDIX SOLUTION

  • Package / Unit-Substations
  • LV Switchgear
  • MV-LV Transformers
  • Modular Power Pods
  • Modular Power Skids

PROJECT CONCLUSION

This skid deployment strategy accelerated the on-site commissioning/startup phase of the project and minimized site works, which proved to be invaluable following the onset of the global Covid-19 pandemic in spring 2020 – given that at peak there were over 6,000 construction workers on site.

Anord Mardix are proud to be part of the successful project delivery of this mega project for such a valued end client and their contracting partner Exyte. Our engineering expertise, operational scale and local manufacturing presence has been crucial to this success and we look forward to working on future FABs with this team.