Precision in Every Molecule: Delivering a Dual-System Spacecraft Integration Facility

Challenge

Building a facility capable of supporting office and lab space, while including both spacecraft integration and advanced environmental testing, is no small feat—and the client needed just that in a single 75,000 SF building. The challenge: accommodate conventional office and laboratory spaces alongside a 30,000 SF high-bay cleanroom, where technicians in full coveralls assemble spacecraft and operate sensitive equipment, such as thermal/anechoic chambers and a 25,000-pound shaker table, at a precise 65°F. The project was further complicated by strict ISO 5–8 cleanroom standards, high electrical loads, and a third-floor finish-out added mid-project, all while maintaining uninterrupted operations.

Solution

Flintco’s preconstruction team collaborated closely with designers and trade partners to deliver two fully independent mechanical systems. Office and laboratory spaces rely on localized humidification, while the spacecraft testing areas are served by fan filter units via fan-coil units, air handler, and a dedicated makeup air unit to maintain precise temperature and humidity control in the high-bay cleanroom.

Primary electrical service was divided between buildings to reduce transformer sizing and optimize costs. Weekly and quarterly pull-planning sessions kept the extended schedule on track, ensuring seamless coordination across trades and phases.

Result

Flintco achieved substantial completion on schedule, with zero safety incidents, successfully balancing the facility’s demanding technical requirements. Operational needs for all user groups were met, cost-saving strategies preserved performance standards, and campus operations continued uninterrupted.