US Fab construction site avoids delays, thanks to Flexiscreen®

Temporary weather protection and cleanroom separation for semiconductor fabs

US semiconductor fab construction has accelerated in recent years. As one of the most expensive, complex forms of construction, these huge construction projects must stay on schedule, without overlooking strict environmental controls. On this manufacturer’s US fab site, the steel frame was up, but permanent cladding and roofing had not yet been constructed. Waiting for the building envelope to be complete before starting cleanroom and interior buildout would blow the schedule. The client needed robust weather and dust protection to allow sensitive internal works to start.
The site location meant that desert dust storms and haboobs presented an additional challenge to the usual construction dust. These weather events can push huge volumes of dust and debris through an open structure in minutes, meaning any temporary protection system had to be designed to withstand wind loading, as well as dust and weather.

Working closely with the contractor and end client, Westgate Global recommended Flexiscreen®, a heavy-duty, engineered temporary weathering system with a proven track record in demanding industrial environments. The solution was needed beyond the US, on the company’s construction projects in Ireland and Israel. Rather than ask the client to commit to an unproven system across multiple continents, Westgate Global installed a full-size live prototype at the Irish site, allowing the team to evaluate structural performance, fire rating, appearance, and suitability before signing off on a global specification.

From prototype to global standard

Satisfied that the prototype met site requirements, the client instructed Westgate Global to proceed with Flexiscreen, achieving a consistent, repeatable global standard. Each location required approximately 54,000 sq ft (5,000 m²) of screening.

A suspended, modular panel system, Flexiscreen was installed from the building’s existing steelwork and tensioned to the floor, making installation quick and clear – especially when compared to other solutions. Calculations from Westgate Global’s engineers ensured the solution met site-specific wind load requirements, with no additional framework or scaffold required. Its unique v-overlap panel connection created a weather- and dust-tight seal, which meets ISO 7 cleanroom standard.

Flexiscreen formed a temporary facade that shielded the internal spaces from weather and dust while the permanent cladding and roofing were completed. Internally, it was used to provide  separation between active construction zones and cleanroom installation areas, preventing contamination from migrating.

One system, three continents, no compromise

Across all three sites, the Flexiscreen installation provided a protected environment that allowed the build to be phased. Weather and dust ingress were successfully controlled and cleanroom zones shielded from construction activity, allowing interior fit-out work to proceed without any delays to the project schedule.

Just as importantly, the client got the same product, the same engineering assurance, and the same project management approach at every location. At the US fab site, where schedule pressure and desert conditions left the least room for error, having a partner who could deliver dust and weather-proofing in a single, reliable solution made all the difference to the project build schedule.

Learn more about Flexiscreen