Cleanroom

Built in Lockheed Martin’s former rocket assembly building, the GPS III Processing Facility (GPF) spans nearly 50,000 square feet of assembly and test areas for new GPS III satellites. The facility features an industry-leading production line that enables highly efficient manufacturing of GPS III satellites. The facility includes:

  • A 32,900-square-foot, SCIF-level, Class 100,000 cleanroom high bay that serves as the “factory floor” and houses assembly stations, a solar array test fixture, and a space vehicle transfer fixture
  • A 960-square-foot thermal vacuum chamber that simulates the conditions of space for testing purposes
  • A 2,880-square-foot, two-story anechoic test chamber that allows for testing of antennas and telemetry equipment without sound or electromagnetic interference

The GPS III program replaced aging GPS satellites while improving capability to meet the evolving needs of military, commercial, and civilian users worldwide. GPS III satellites deliver enhanced accuracy and improved anti-jamming capability, extend the spacecraft’s design life, and add a new civil signal interoperable with international global navigation satellite systems.

As the project’s electrical engineer, RMH designed normal and backup power systems, lighting, grounding, fire alarm system detection and notification, lightning protection, access control, and public address systems for this critical facility.

Photo credit: Lockheed Martin Space Systems

BAE System’s specialized testing and manufacturing facilities support critical space missions, including the James Webb Space Telescope (JWST) program. The 4,042-square-foot clean/non-destructive test lab was developed to thoroughly clean and test critical flight hardware for national asset programs. As the next-generation Hubble Telescope, the infrared JWST enables astronomers to study the entire history of the universe. The lab’s built-in flexibility accommodates testing and cleaning for other satellite missions as well.

The lab’s large parts spray room, where bulkier flight hardware is cleaned with hazardous solvents, features an innovative air-diffusion system that delivers evenly distributed, cleanroom-quality airflow. This system moves vapors away from staff and limits flammability risks. Building Information Modeling (BIM) software was used to design large, complex ductwork for the small ceiling plenums in the spray rooms. Additional safety measures include applying intrinsically safe process piping controls to limit voltages in the presence of flammable vapors and developing a chemical container emergency depressurization system.

As the project’s mechanical and electrical engineer, RMH designed custom air systems to address the limited plenum space. The design incorporated vertical unidirectional airflow using fan-filter units, a custom hood, hazardous exhaust systems, and point-of-use laboratory systems, including nitrogen, house vacuum, deionized water, and dust collection. Electrical systems included electrostatic discharge protection, heavy power for support equipment, photosensitive “yellow” lighting, branch grounding, and overhead hoist electrical systems.

STAQ Pharma is transforming pediatric healthcare by addressing a critical gap in the pharmaceutical supply chain: the availability of sterile, small-dose medications for children. At its cutting-edge 18,400-square-foot cGMP 503B outsourcing facility in Colorado, this innovative startup repackages adult-dose medications into precise pediatric doses using advanced robotic automation. These smaller doses are essential for pre-operative, operative, and post-operative procedures in pediatric care.
The facility includes 5,000 square feet of highly automated cleanroom space designed to meet the highest standards for sterile-to-sterile drug repackaging. Robotic systems ensure exceptional sterility, accuracy, and efficiency, helping STAQ Pharma deliver safer and more reliable medications for pediatric patients.

To support this pharmaceutical-grade environment, the HVAC system maintains an ISO 7 cleanroom classification through a cascading clean-to-dirty pressure hierarchy. Inside the robotics enclosure, conditions are even more stringent, achieving ISO 5 classification. Energy-efficient design strategies, including variable airflow modes for occupied and idle states, enable significant energy savings while maintaining strict air-change requirements.

The Lockheed Martin Space Systems Gateway Center at the Waterton Canyon campus marks a significant leap in satellite production capabilities. This $350 million, 266,000-square-foot facility focuses on designing, manufacturing, and testing satellites. Within its expansive layout, 175,000 square feet of SCIF support secure operations for national security missions.

The Gateway Center features a high bay Class 100k clean room, enabling the simultaneous construction and testing of large and small satellites. It also houses a large thermal vacuum chamber that replicates the harsh conditions of space, allowing for rigorous satellite testing prior to launch. Complementing these facilities is a sizable anechoic chamber for safely testing satellite antennas, sensors, and communication systems, as well as a large volume airlock that streams the departure of completed spacecraft in a controlled, clean environment.

The project includes redundant power systems, uninterruptible power supplies, generators, and a central utility plant, achieved through meticulously coordinating highly technical equipment.

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