Several studies were conducted when determining the deployment site, due to the plant's extremely high technical and planning levels. Implosion tests were conducted around a ten-kilometer radius to determine ground vibration levels, which should be equivalent to zero.
The ground vibration levels emanating from the BR 040 highway, connecting Belo Horizonte to Brasília, were also measured. It presented significant vibration impact, and baseline readings were decisive for the project design and choice of construction materials and systems.
Environmental control was another critical factor to establish project guidelines and construction techniques. An environmental preservation perimeter of about 56,000 m² was set up, which corresponds to almost a third of the total property area (160,000 m²).
Soil was reused in the levelling process. It was excavated and moved within the plot and did not require any kind of external transport.
Meeting these requirements was essential to promote initial understanding of the project and its premise, since high-tech industries need to preserve the environment to ensure their operations.
The project's main challenge lay in meeting all the production and environment requirements of the so-called Clean Room. There, tiny parts can't be spoiled by any element foreign to the production process.
Air and water used in the production process must meet ideal purity levels, while temperature must remain constant. Trepidations and vibrations need to be neutralized, just as the power supply must not be interrupted, even for a split second.
The production of semiconductors requires that the 4,200 m2 area be isolated, under invariable conditions and at constant operations, and not subject to internal or external vibrations.
The Clean Room should be 100 times more sterile than an operating room.
Matec differentiating factor
The construction of a semiconductor plant requires creative design and strict implementation techniques at the same time. The Matec team understands the full semiconductor production process, and can skillfully coordinate an international team formed by Brazilian, German and American designers and consultants.
A couple of traditional engineering principles had to be revisited. As an example, we started building the plant from the first floor. The reason behind this decision was to ensure there would be no interruptions after the plant went operational.
Due to the need for uninterrupted power supply, two separate transmission lines were designed. Each of them is powered by a different source, thus ensuring continuous supply in case the other one fails. Due to these specific requirements, the entire building system was double planned.
The entire architecture, materials and construction were carefully considered so as to meet such demands. It was our job to find precise solutions for floor thickness, slab size, supply systems and closings.
Due to the high complexity of the project facilities, the entire plant was modeled and managed with BIM. The tool provides high precision in the design process, and lays every installation in its right place, ensuring they don't overlap or interfere with the other subsystems.
It was necessary to achieve excellence from conception to execution.
The contractual term was 24 months, three of which were allocated to project development and contracting required to start construction, under a "design to build" contract.