Overview

A fast-growing start-up partnered with Airtho to convert a former IBM manufacturing plant into a fully functional, large-scale cleanroom environment. The project required leveraging existing building infrastructure, rapidly developing custom-engineered spaces, and maintaining a tight budget and schedule while technical needs continued to evolve.

Challenge

The client needed to transform a substantial 55,000 ft² industrial space into a modern controlled environment with minimal disruption and maximum reuse of existing systems. The project demanded rapid design output, ongoing customization, and the agility to respond to shifting operational requirements typical of a start-up scaling quickly.

Solution

Airtho delivered a highly coordinated solution that blended adaptability, engineering precision, and efficient use of existing resources:

• Conversion of Existing Facility: The former IBM manufacturing plant was repurposed to support the client’s new production environment, maximizing the value of existing infrastructure and reducing the need for costly demolition or reconstruction.

• Leveraging Building Infrastructure: Airtho integrated the structure’s existing steel and chilled water system to provide efficient in-room sensible cooling. This approach minimized mechanical complexity and supported long-term reliability.

• Hybrid Pre-Engineered + Custom Design: The project combined Airtho’s pre-engineered components with fully custom areas, enabling precise and complete design submittals in just six weeks, despite the scale and complexity of the facility.

• Rapid Adaptability: With evolving technical requirements and a tightly managed budget, Airtho’s project team remained flexible throughout design, construction, and start-up—enabling the client to stay on schedule without compromising performance.

• Energy-Efficient Mechanical Design: Placing the desiccant dehumidification unit (DHU) directly on top of the room allowed for an efficient duct layout. Combined with high-efficiency terminal HEPA filters, the final design delivered exceptional performance with only 2.5 inches of total external static pressure.

Results

• Successful conversion of a legacy manufacturing facility

• Efficient reuse of structural steel and chilled water systems

• Complete, accurate design submittals delivered within six weeks

• Project executed on a fast-track schedule with continued budget and scope flexibility