Overview

Airtho was selected to design and deliver a controlled dry room environment with an adjacent fire-rated Mixing Room inside an active R&D and production facility. The project required integrating pre-engineered systems into an existing building while coordinating multiple trades, mechanical systems, and architectural components on a fast-paced schedule. Through comprehensive planning and adaptable field execution, Airtho delivered a fully operational space meeting stringent environmental requirements.

Challenge

This project involved a series of technical and logistical complexities:

• Incorporating a fire-rated Mixing Room alongside the main dry room environment

• Working within limited interior staging and laydown space

• Integrating mechanical, electrical, and plumbing systems inside an active facility

• Coordinating construction sequencing between the dry room, plenum cap, wall systems, Intelligrid™, and equipment installation

• Ensuring accurate pressure control, airflow performance, and system startup in a high-precision environment

These conditions required detailed coordination, clear communication between all teams, and flexibility throughout construction.

Solution

• Integrated Construction Approach: A phased installation plan allowed the project to progress efficiently, beginning with flooring and the Mixing Room, followed by dry room walls, Intelligrid™ ceiling, plenum components, windows, doors, and RCP elements. Continuous field verification ensured that all architectural and mechanical systems aligned with existing building conditions.

• Mechanical System Implementation: Airtho oversaw the installation of the desiccant dehumidification unit (DHU), chiller, pump package, and associated ductwork. Startup procedures included pressure balancing, airflow verification, and calibration of the control systems to ensure optimal performance.

• Electrical & Controls Coordination: The electrical team installed FFU circuits, overhead utilities, sensor systems, door interlocks, and lighting components. Adjustments were made as needed to integrate with ceiling systems, equipment layouts, and building pathways.

• Plumbing & Hydronic Integration: Chilled-water piping, condensate management, and pump connections were completed in coordination with mechanical equipment placement. System testing included pressure checks, flow verification, and final adjustments to support stable operation.

• Quality Assurance & Commissioning: Final commissioning included DHU and chiller startup, FFU verification, pressure testing, and comprehensive walk-throughs with the onsite team. Airtho provided clear documentation and ensured the environment met the project’s design criteria and environmental performance goals.

Results

• Delivered a fully commissioned dry room and fire-rated Mixing Room

• Integrated architectural, mechanical, electrical, and plumbing systems within an active facility

• Achieved stable room pressures, airflow performance, and environmental control

• Completed the project through a coordinated, adaptable construction process

• Provided a turnkey environment that supports advanced battery research and production activities