Manufacturing Award of Merit: Broadcom Limited Expansion and Renovation

Broadcom Ltd Expansion and Renovation — The renovation project involved converting 8,000 sq ft of office space into clean rooms for manufacturing, along with building out an additional 43,000 sq ft of clean-room fabrication space. The team also expanded warehouse space by 125,500 sq ft and added 20,000 sq ft of clean-testing space, along with offices for more than 200 employees.

*Photo courtesy of JE Dunn Construction*

Broadcom Limited Expansion and Renovation
Fort Collins, Colo.
Award of Merit

Owner: Broadcom Limited
Lead Design Firm/MEP Engineer: Mazzetti+GBA
General Contractor: JE Dunn Construction Co.
Civil/Structural Engineer: Martin/Martin Inc. Consulting Engineers
Design Architect: Burkettdesign Inc. (EUA)
Owner’s Rep: CPI Group
Subcontractors: Encore Electric Inc.; US Engineering Co.; Western States Fire Protection Co.; National Coatings Inc.; Kenny Electric Service Inc.; Horizon Glass & Glazing Co.

To expand Broadcom’s semiconductor plant in Fort Collins, Colo., the contractor had to make sure construction didn’t interfere with production. During the first 60 days, the team met three times a week to determine how to guide the project around manufacturing operations. A key segment of the project converted 8,000 sq ft of office space into clean rooms for manufacturing, along with building out an additional 43,000 sq ft of clean-room fabrication space. Another portion expanded warehouse space by 125,500 sq ft and added 20,000 sq ft of ISO-compliant, clean-testing space, along with offices for more than 200 employees.

The clean-room fabrication space was built on a “cheese slab”—a cast-in-place concrete layer perforated with more than 8,000 holes on 2-ft centers. The 8- and 16-in. holes allow air to flow into the 43,000-sq-ft fabrication space and enable mechanical, electrical and plumbing trades to run services without penetrating the slab or running ductwork.