ASCI WEST CHICAGO, IL

The addition for American Standard  Circuits Inc. consists of a 20,000 sq. ft. warehouse facility dedicated to  the manufacturing of circuit boards. The mechanical, electrical, and plumbing  systems were designed by 3S MEP+S, providing a fully coordinated and  efficient building systems solution tailored to the operational requirements  of the facility.

The Mechanical team performed  detailed heating afnd cooling load calculations for the PCB manufacturing  facility to determine the HVAC requirements for the various production,  testing, office, and support spaces. The facility included layup rooms, layup  preparation and dipping areas, quality control spaces, electric testing  departments, multilayer manufacturing areas, maintenance shops, offices,  storage rooms, and the plating floor.

Rooftop units (RTUs) were selected  and sized to provide temperature control, ventilation, and occupant comfort  throughout the office and manufacturing areas. Air distribution systems were  carefully designed to provide balanced airflow while accommodating equipment  layouts and process requirements. Ventilation rates were established in  accordance with applicable mechanical codes and industry standards to  maintain indoor air quality and support manufacturing operations.

A significant portion of the  mechanical design focused on the plating floor, where process exhaust  requirements necessitated the installation of a dedicated make-up air unit  (MAU). The MAU was designed to provide conditioned outdoor air during both  summer and winter operating conditions, ensuring proper building pressure  control and replacement of exhausted air. Roof-mounted exhaust fans were  designed and sized to remove process-generated contaminants and comply with  code-required exhaust rates. The mechanical systems were coordinated with  architectural, structural, and process equipment layouts to ensure efficient  operation, serviceability, and constructability.

The Plumbing team designed the  domestic water, sanitary waste, and natural gas systems using the existing  building utility services. Domestic water and sanitary piping were provided  for the new restrooms and support areas in accordance with applicable plumbing  codes.

To connect the new restroom  addition to the existing sanitary system, a sewage ejector pump was designed  to discharge wastewater to the existing sanitary manhole. This approach  reduced the complexity of routing new sanitary piping through the existing building  and minimized construction impacts.

The natural gas piping system was  also designed to serve gas-fired mechanical equipment. Overall, the plumbing  design provided a simple, efficient, and cost-effective solution while  utilizing the existing utility infrastructure.

A comprehensive electrical scope was developed, including the design of lighting systems and power distribution networks in accordance with the applicable National Electrical Code (NEC) requirements. The lighting layout  was designed to provide adequate illumination levels for warehouse and manufacturing operations while optimizing energy efficiency. Lighting control  strategies were implemented using occupancy sensors integrated with a  Bluetooth Low Energy (BLE) mesh control system, enabling intelligent lighting management and enhanced energy savings.

One of the primary challenges of the project was designing an efficient power distribution system for the 20,000 sq. ft. manufacturing facility while  controlling voltage drop and installation costs. Detailed distribution studies were performed, leading to the strategic placement of the electrical room near the center of the building. This configuration minimized feeder and  branch-circuit distances, reduced conductor quantities, improved voltage  regulation at utilization equipment, and enhanced the overall efficiency of  the electrical infrastructure.

Detailed  engineering analyses were conducted, including electrical load calculations for proper service and distribution equipment sizing, as well as fault current calculations throughout the distribution system, extending to the rooftop units (RTUs). The fault current study was performed to verify available fault current levels and ensure that all RTUs and associated  electrical equipment were provided with adequate Short-Circuit Current  Ratings (SCCR) for safe and code-compliant operation. The power distribution  system was engineered to support manufacturing equipment loads and facility  operations while ensuring reliability, safety, and compliance with NEC  requirements.

With all  3S MEP+S projects, a primary focus is on integrating MEP and structural  designs with the construction and architectural partners and the end-users to minimize the need for design adjustments or revisions during the construction  process. Design teams from 3S MEP+S actively engage with all stakeholders to identify potential conflicts and optimize the overall system layout. Our  teams are exceptionally proficient at harmonizing essential building elements  for successful outcomes.

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