LED Manufacturing Facility Syracuse, NY
NexGen Power Systems is revolutionizing power electronics with technology solutions utilizing GaN on GaN discrete semiconductor devices, modules, and systems that increase efficiency and reliability of power conversion systems while dramatically reducing their cost, size, and weight. We have assembled a world-class team of engineers with proven track records in inventing, developing, and commercializing semiconductor technologies. Our internal expertise and competence encompasses GaN epitaxial growth, materials characterization, device design and processing, electrical characterization, reliability testing, and product development. Our focus is in developing and manufacturing vertical power semiconductor devices built in homoepitaxial GaN layers formed on bulk GaN substrates. We have established licensing and supply agreements with multiple GaN substrate vendors, giving us access to the highest quality and lowest cost bulk GaN substrates.
Our vision is to create the smallest, lightest, most cost-effective power conversion systems in the world. Power conversion systems are at the heart of almost every electronic device from home appliances to data centers, laptops, and electric cars. They are what help convert an AC source to DC either as an adapter that plugs into the wall or as component internal to the device. The technology is a pervasive part of a $68 billion global market. The problem is, today’s power systems are based on decades-old technology that is large, inefficient and run hot. That wastes energy… and money. We’re out to change all that… NexGen Power Systems is changing the power electronics equation with highly proprietary technology solutions in discrete semiconductor devices, modules, and system architectures that increase the efficiency of power conversion systems while dramatically reducing their cost, size, and weight. Power-hungry electronics are becoming more and more ubiquitous, generating unprecedented demand for more efficient power conversion. The power conversion market is staged for tremendous growth. However, today’s underlying technologies are greatly antiquated and unable to keep up with our insatiable desire for smaller, lighter, more efficient and cost-effective solutions.
NexGen Power Systems recognized early on that revolutionary changes to this change averse market would only come through transformational innovation in the heart of all power conversion systems—the semiconductor switch or transistor. A switch that could operate at much higher frequencies and voltages would enable conversion circuit topologies that are inherently more efficient and conducive to passive component reduction. We have assembled a world-class team of engineers with proven track records in inventing, developing, and commercializing semiconductor and power conversion
Site Features The parking lot is situated on the north end of the site and can accommodate 150 spaces for both staff and visitors. The building orientation frames a two-sided courtyard that will feature an outdoor patio area of approximately 2,000 square feet. The patio area will be accentuated with concrete pavers and green landscape elements. All exterior egress doors will open to the courtyard and adjacent parking lot. The loading areas and bulk gas storage yards are located on the southern end of the site. The chem dock will be at grade to accommodate hand-truck delivery access. The shipping/receiving area will have a 4’ recessed loading dock supported by (2) site retention walls. There is a chiller plant and generator that will be located on the western edge of the site. There are (2) curb cuts off of Collamer Crossing Parkway that create a loop road around the facility with controlled limited access into the loading and gas yards by a site perimeter fence and (2) manually operated access gates.
Building Design, Programming & Organization The building is orientated longitudinally on site along the north/south axis and consists of four main elements; office space, manufacturing spaces (including cleanrooms and parts assembly) building support and expansion space. The office wing is situated on the northern end of the building and has an approximate roof height of 17’. It will be isolated from the manufacturing wing with a continuous 2” expansion joint. The office is designed to accommodate 70 workstations in an open office layout with most of those individuals working normal business hours. The manufacturing support space, and expansion space occupy the remainder of the building and have an approximate roof height of 42’. The manufacturing element is expected to operate 24 hours a day, 365 days a year with minimal interruptions. The expected shift breakdown to support the operation is (4) 12 hour shifts with approximately (35) individuals per shift. The expansion space is located to the eastern side of the manufacturing wing. This space is intended to be left unfinished with minimal MEP support as dictated by the life safety support. The north and east façade of the building will be the building’s most visible presence from Collamer Crossing Parkway. There are existing deciduous trees that currently line Collamer Crossing Parkway that will be removed to allow frontage access to the building as well as provide an intentional view of the building from the primary vehicular approach. The trees that are removed will be replaced with new landscape elements that are more appropriately spaced for screening purposes and frontage access. While the more prominent architectural feature will be the attached office wing, the cleanroom, cleanroom support areas, manufacturing, assembly, warehouse, and other support spaces will make up the larger proportion of the building mass. The primary building material utilized is insulated metal wall panels (30’x20’ and 30’x10’ horizontal orientation). To help break-up the scale of the larger manufacturing mass, some of the 30’x20’ insulated metal horizontal panels will be segmented by using a series of integrated metal reveals and horizontal joints of varying widths. The panels will be a mix of (3) monochromatic colors that are staggered in elevation in a random manner. There are fixed integrated aluminum windows strategically placed along the eastern façade of the manufacturing wing to bring daylight into the expansion space. The office wing is comprised of insulated metal panels (30”x8’ horizontal orientation), aluminum curtain wall and terracotta rain screen. There are fixed integrated aluminum windows placed in all office wing metal panel walls. The terracotta rain screen system is limited to the multi-purpose room rotunda wall. There are punched aluminum windows in the rotunda that will receive horizontal terracotta sun-shade baguettes. The aluminum curtain wall will be a high performance pressure glazed system with a 1” low-E coated insulated glazing unit. Depending on the elevation, there will either be a low profile snap-on face cover or a 14” deep extruded snapon fin. These fins will be strategically placed to shade direct sunlight into the open office. To allow natural ventilation to the open office, there will be numerous operable sashes in the curtain wall system.
Code Summary The following codes are applicable to this project: 2010 Building Codes of New York State (BCNYS)(based on 2006 International Building Code) 2010 Fire Code of New York State 2010 Plumbing Code of New York State 2010 Mechanical Code of New York State 2008 National Electrical Code ICC A117.1 – 2003 Accessibility Code 2004 Energy Conservation Code of New York State The building was designed as construction Type IIB (non-combustible, full sprinkler protection) with mixed, separated occupancies: B, F-1, H-2, H-3, H-5 & S-1. B: F-1: H-2: H-3: H-4: H-5: S-1:
Single tenancy office space that shares purposes with manufacturing Manufacturing support spaces and prototyping space Chemical storage Chemical storage Chemical storage Manufacturing with use of chemicals Shipping/Receiving Storage
This is a (2) story building where the second story is a partial floor designated entirely for MEP support space. The second story will have two dedicated egress stairs that exit directly outside. As a multi-story building, a minimum 5/8” thermal barrier will be required in the exterior wall assembly to isolate the combustible plastic from the occupied space (per NFPA 285). As a mixed, separated type IIB building, the different occupancies will be separated by a minimum 1-hr fire barrier. HPM chemical storage rooms will receive 2-hr CMU partitions. The second story floor slab will be composite metal floor with a fire rating of 2-hr. Where occupancies above differ from the occupancies below, the supporting floor structure will receive a 1-hr or 2-hr cementious based sprayfireproofing that extends a full column bay beyond the extent of the differing occupancies. The exterior slab edge will need to receive a 2-hr fire-stopping system as approved by 3M (or comparable entity) that extends the fire rating to the inside face of the exterior insulated metal wall panel. In order to meet an allowable area ratio less than 1.0 per section 508.3.3.2 of the 2010 BCNYS, this building will be dependent on both an automatic sprinkler increase and a frontage increase (per section 506 of the 2010 BCNYS). As we currently stand, the building can be constructed without a firewall separating the office wing and the manufacturing wing. Listed below, are the factors that could alter that decision: Building Area The building is two stories with a total gross area of 82,250 sf. The area breakdown is as follows: LEVEL 01 Office Building Footprint 12,300 sf Manufacturing Building Footprint 42,900 sf Expansion Footprint 11,350 sf LEVEL 02 Manufacturing Support 82,250 sf
15,700 sf
Future MEP equipment or chemical storage equipment is placed on site within 30’ of the building. The occupancy classification(s) in the Expansion Space change. As we currently stand, 50% of this space will be utilized for a Business Occupancy and 50% will be utilized for Factory Industrial F-1 Moderate-Hazard Occupancy. The occupancy classifications in the remainder of the building change. If any of the above factors occur, the frontage increase factor will be effected and the allowable area calculations will need to be re-examined to determine if a 3-hr fire-wall is necessary between the office and manufacturing wings.
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EAST ELEVATION Sustainable Design Sustainable design principles will be employed as a matter of sound design practice. Energy efficient design is essential element of the team’s standard design philosophy and project planning process. For this project, the team will promote the use of efficient and renewable concepts, materials and resources wherever and whenever possible.
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