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Delivering Engineering Excellence in Sensitive and Secure Environments

By Kelsey Rowe, PE, CLD

May 28, 2025
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At Design Collaborative, we pride ourselves on solving complex engineering challenges—and some of the most impressive work we do happens behind the scenes, in environments where discretion, precision, and reliability are paramount.

One of our recent projects involved a highly specialized facility undergoing both renovation and expansion—all while remaining operational. The project demanded intensive planning, flexible design strategies, and close coordination across disciplines to meet the client’s unique requirements without disrupting critical ongoing work.
Large industrial room with yellow beams.
Large industrial room with yellow beams.

Designing for Complexity Within an Active Facility

Our team was tasked with integrating new infrastructure into an active, secure facility, which meant we had to design around existing conditions, limited ceiling space, and aging building systems. Phasing was critical; every piece of construction was planned to minimize disruption, especially in areas where ongoing laboratory operations could not be paused.

Precision Planning for Sensitive Operations

Due to the sensitive nature of the work conducted in the facility, coordinated outages and system transitions had to be carefully staged and timed—often down to the minute. We worked hand-in-hand with facility stakeholders to plan electrical and HVAC transitions that maintained operational continuity and protected the integrity of the lab environment at all times.

Secure Construction from the Ground Up

Security requirements influenced every layer of design and construction. From specialized materials and building assemblies to access control systems and compartmentalized infrastructure, we ensured that every space met the criteria necessary for the work being performed within it.

Power and Resilience You Can Count On

Uninterrupted power was a top priority. The building is now supported by:

  • Multiple >1 MW diesel generators, with a combined capacity sufficient to power more than 170 homes
  • Advanced transfer switching with built-in load shedding options, ensuring critical systems remain online during emergencies
  • A centralized UPS system backed by 85 high-capacity batteries, protecting sensitive equipment and maintaining power quality across the lab environment
  • A new utility switch and medium voltage transformers, designed to handle both the renovated and new spaces efficiently

Designing Flexibility Into the Foundation

In an environment where lab configurations and equipment change frequently, flexibility isn’t a luxury—it’s a necessity. We designed and installed a custom in-floor utility distribution system that allows connection to power, data, compressed air, and gas throughout the space, enabling rapid reconfiguration as project needs evolve.

Total Environmental Control

Given the stringent environmental needs of the labs, we delivered:

  • Fully redundant HVAC systems to ensure 24/7 uptime
  • Clean room-level air quality, with HEPA filtration, pressure-controlled zones, and high-performance ceiling systems
  • Air changes rates in individual spaces to meet ISO 5 to ISO 8 cleanroom requirements dependent on room usage, ensuring a continuously refreshed, contaminant-free environment

Built for Coordination

Much of this infrastructure was housed within a pre-engineered metal building, which required exceptionally close coordination between MEP engineers and the structural team. With miles of conduit, piping, and ductwork running through every inch of the space, early collaboration and 3D modeling were key to success.

By the Numbers: A Few Fun Facts

  • The building’s main electrical service could power about 210 average-sized homes
  • The diesel generator consumes 141 gallons/hour at full load (compare that to 3 gallons/hour for a Dodge Ram at 60 mph)
  • The UPS battery system includes 85 batteries, each cabinet weighing over 1,000 lbs
  • 3400 gallons of diesel fuel are stored on-site
  • Over 6.5 miles of piping was installed
  • The cooling system output could serve 560 homes

This project is a prime example of how our team rises to meet the unique challenges our clients bring us. Whether you’re expanding a secure facility, retrofitting a critical operations space, or building from the ground up—we bring deep technical experience, agile coordination, and a commitment to getting it right the first time.

If your next project demands absolute precision, uninterrupted performance, and mechanical and electrical engineering solutions that adapt to the most complex and secure environments, let’s talk about how we can support you. Reach out to our team to start a conversation about your next high-stakes build.

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