Advanced Manufacturing

Lead times on engineered equipment are the single biggest schedule variable on manufacturing work right now, and they move quarter to quarter. We track them rather than estimate them.

Clayco publishes a quarterly Cost Index covering material pricing, labor conditions, tariffs, procurement and regional market activity. We use it to set realistic durations at the front end rather than discovering a problem at buyout.

However, it is reasonable to assume electrical components like switchgear, substations, buss duct will be in short supply, as well as large chillers, boilers, specialized air handling equipment.

Pre-purchase decisions get made early is design and preconstruction or they get made too late. Our recommendation is driven by two things: what has the longest lead time, and what the design is least likely to change.

We handle pre-purchase through our integrated Engineering, Procurement, Construction and Verification approach, which puts procurement in the room during design rather than after it. That lets us lock specifications on long-lead items while the rest of the design continues to develop.

Yes, and we have done it next to operations that could not stop.  Most manufacturing facilities must expand while operating at some time and Clayco manages these regularly.

Phase 2 for a confidential client expansion in Spartanburg, South Carolina added 300,000 square feet of production space alongside an active chemical facility. The work included more than 500 ground improvement piers, an 8-foot-thick mat slab, specialized wastewater systems and 3,800 tons of structural steel, all completed without disrupting ongoing operations.

That work took coordination at every stage: sequencing around production schedules, managing utility tie-ins and shutdowns against the customer’s calendar rather than ours, and keeping logistics and craft traffic separated from operating areas.

Yes, detailed subfab coordination is required in semiconductor facilities. The plan must be detailed to the point where subfab pipe and utility racks can be fabricated and stocked off-site utilizing composite work teams. Precise use of BIM technology allows this to happen.

All utility racks in wafer fabs are constructed based on modular concepts that are developed in the design phase. The utility racks are based upon grids/column lines that were established early in the design phase.

The logic transfers directly to automotive and other industries. Our design team looks for modularity options in structure, building closure, utilities. Any item that is repetitive, utility-dense and on the critical path is a candidate. Building it in a factory removes it from weather, from site congestion and from trade stacking.

Clayco has developed very accurate cost models that have proven reliable during the very early stages of project design. Our models are based on throughput (JPH), factory automation philosophy (floor supported versus structure supported), expected electrical loads and distribution methods, HVAC scheme (chilled water versus DX systems).

Clayco recommends the Guaranteed Maximum Price (GMP) form of contract as the best all-around but we are open to discussing all contract formats.