EV Battery Facilities The Ardmac Way
EV Battery – Dry Cleanrooms The Ardmac Way
ARDMAC
Return Air Walls
02 ABOUT ARDMAC
FFU and Grid Cleanroom Ceiling Grid Construction
04 CAPABILITIES
Leveraging our extensive knowledge and experience in the cleanroom sector, Ardmac have the right technical solutions to respond to the increasing demands of the EV industry. Ardmac is an international construction specialist that delivers complex high value workspaces and technical environments. At Ardmac, our reputation is built by delivering results and exceeding client expectations. Ardmac provides high-tech data centre solutions and to date has provided over 450,000 m² of white space and 600mw capacity for industry leading clients across Europe. Ardmac also specialise in cleanroom facilities and have provided over 200,000 m² of cleanroom space over the past 6 years. We have a proven track record of delivering high performance, innovative and future proof solutions.
06 THE ARDMAC WAY
PLENUM ZONE
08 APPLICATIONS & REQUIREMENTS 10 MANUFACTURING & CONTAMINATION
Cooling Coils
12 WORKING SMART
It is this experience combined that allows us to offer a fast-track dry cleanroom construction solution.
ANTI-STATIC FLOORING
17 CASE STUDY
18 MEET THE TEAM
Cleanroom Panel Inner Wall
Vapour Barriers
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In line with the rapid increase in the use of electric vehicles worldwide, the global lithium-ion battery market size is expected to expand at a CAGR of 18.1% from 2022 and reach $182 billion by 2030, according to a recent report by Grand View Research, Inc. Key to this target being achieved will be the availability of suitable giga-battery manufacturing facilities. Given the reactive nature of lithium, specialised closely controlled dry room environments are critical to the manufacturing process for high-quality lithium-ion batteries. This requires the application of cleanroom and humidity control technologies coupled with the expertise of our teams to deliver ultra-low RH clean facilities. Ardmac have developed a number of design solutions, tailored to suit your project’s specific requirements in relation to your dry cleanroom performance. With 45 years of experience in the successful delivery of close controlled environments for the advanced technology sector, Ardmac and our specialist partners are ideally positioned to deliver your next EVBF manufacturing facility.
Dry cleanrooms are hermetically sealed rooms, along with mini-environments that contain and maintain ultra-low humidity levels while also controlling airborne particle concentrations and static discharges. Specific requirements for such facilities can vary but would typically be ISO Class 6 – 8 cleanroom, with Relative Humidity level of <1% or a Dew Point of -50° celsius. Regardless of whether it is a small-scale R&D facility or a large scale giga-plant, the same design principles will be applied. Ardmac want to help you Power the Future
The design solution required to achieve ideal dry cleanroom conditions are made up of 2 critical elements and matching the architectural envelope with the HVAC system; they must be indivisible. The architectural envelope is responsible for meeting the requirements in relation to the provision of a hermetically sealed room.
The HVAC system is responsible for ensuring that the required temperature, humidity levels and airborne particle concentrations are maintained. While the design principles for dry cleanrooms remain consistent,
Room occupancy levels
Room exhaust rates
Required temperature and relatively humidity levels & control bandwidths
Process workflows and equipment layouts
Material and people flows and airlock barriers i.e. MALs and PALs Ideal dry cleanroom conditions with a safe pair of hands
Physical room dimensions
Sensible internal heat loads
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Intelligent Design Dry cleanrooms require an integrated design of each contamination risk element. There can be no split responsibilities over performance and accountability; this only leads to over design and inefficiencies, with an unnecessary increase in capital expenditure and then operational expenditure. Smart Control Every extra gram of moisture that has to be treated adds an unnecessary cost. Ardmac uses ‘Smart’ adaptive demand based control, with continuous monitoring of critical environmental parameters of moisture content, airborne particles and static charge levels. This real-time information, when coupled with integrated control of MALs and PALs ensures no moisture ingress during operations and precise contamination control, in the most efficient and cost effective manner. Energy Efficient Ardmac has a particular expertise in dry cleanrooms and integrating ‘Smart’ HVAC systems and desiccant dryers. ‘Smart’ design principles are important when developing airlocks (MALs & PALs) to control air infiltration before it gets into the dry cleanroom and sensitive lithium- ion battery processes. Air leakage and unnecessary moisture treatment are the unseen enemies of good operational efficiencies and OPEX control.
Working Smart Ardmac work ‘Smart’, meaning we deploy innovative and integrated technologies throughout our business to coordinate our building processes and drive performance. We apply Lean construction and cloud based collaboration tools including BIM, Last Planner, GoContractor and Procore to maximise value for our clients. By implementing these powerful tools, clients are directly embedded in the process and can see project performance in real time. Firestopping and Safeguarding There are inherent safety hazards involved with Li battery manufacturing processes, in particular, as their electrolytes are flammable by nature. Ardmac fire compartmentation for process segregation and isolation, for example those areas around aging ovens. provide dedicated In addition, off-gas monitoring is critical to guard against thermal runaway, which is an exothermic reaction in which lithium- ion battery cell temperatures rise rapidly in an uncontrollable manner, and toxic gases are vented, increasing the risk of personnel safety, fire and explosions.
Scale and Speed of Delivery Ardmac’s ability to deliver these fast track giga battery facilities is demonstrated by our proven ability to deliver complex large scale data centres and microelectronic facilities across the UK and Europe. There is no room for errors, either in design, co-ordination or execution to commissioning, performance verification, certification, handover and start-up. Speed of volume production is critical in this fast changing EV landscape. Vapour Shield Ardmac’s Vapour Shield approach – Ardmac are specialists in providing controlled environments with moisture and particle containment at the centre of our focus. We ensure all penetrations and joints are designed with vapour permeability in mind. This includes the entry and exit MAL and PAL barriers to moisture ingress.
DRY CLEANROOMS THE WAY
INTELLIGENT DESIGN
SMART CONTROL
ENERGY EFFICENT
WORKING SMART
FIRESTOPPING
SCALE AND SPEED
Certainty of performance
VAPOUR SHIELD
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Giga Battery Applications High technology applications require working in precisely controlled environmental conditions. Lithium battery application is fast growing across diversified industries like Electronics, Automotive, Electric Vehicles (EV), Energy Storage, Solar, Telecom, Power, Defence, Space/Satellite, Healthcare etc. The lithium-ions are the carrier that creates the battery power, but lithium is only a component of a complex battery system. A lithium-ion battery is made up of four primary components.
Dry Cleanroom Requirements Pure lithium metal is extremely sensitive to even tiny amounts of moisture in the air and leads to reduced performance and reliability over the battery lifecycle. When lithium gets in contact with water, lithium hydroxide is formed, which is a highly flammable hydrogen, i.e. (Li + H2O) = (LiOH + H2). With the latest LI chemistries, lithium salts used to keep the electrolytes stable. In some chemistries moisture leads to the generation of hydrogen fluoride as an undesired by-product, which leads to gassing and bloating up of Prismatic and Pouch batteries, thereby reducing performance and life expectancy.
Learn More
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Electrode Manufacturing Raw materials are combined to produce a slurry material; this is coated onto a metallic substrate producing. Individual Anode & Cathode electrodes. The anode & cathode materials must be kept separate, at all times in order to prevent contamination. Cell Assembly (Cylindrical/Pouch) The Electrodes are brought together but separated by a ‘Separator’. The electrolyte solution is injected into the cell. Formation, Aging & Testing During the formation process, the cell receives it first electrical charge. A process of charging & discharging forms a protective layer on the electrodes. This protects the active material from the electrolyte solution. Module Assembly Individual cells are mechanically connected to form the battery module.
EV battery manufacturing processes are complex, sensitive, and delicate, in a multi-stage sequence with mixing, pumping, coating, injection, calendering, ageing and assembly operations. EV battery contaminants include moisture, particles and static, as well as chemical and electrical fire and safety risks. Therefore, robotics and automation are extensively used along with mini environment, to provide both product component protection and personnel safety. Typically, there are 4 processes to EV battery manufacturing. The following process steps are indicative of a typical battery, chemistries, and technologies. These process steps are carried out in multiple and different interconnected dry cleanrooms and storage areas, within the overall EV battery manufacturing facility
MANUFACTURING PROCESSES AND CONTAMINATION CONTROL
ELECTRODE MANUFACTURING
CELL ASSEMBLY
FORMATION, AGING & TESTING
MODULE ASSEMBLY
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WORKING SMART THE WAY
We empower our people with highly effective collaboration through ‘Early Contractor Engagement’ and extensive BIM adoption using latest technologies. We maintain Lean streamlined workflows, utilising user friendly cloud based field management platforms to empower our people with realtime accurate information in the field, on any device. We drive performance with safe projects. Our digital onboarding and resource management systems control quality and allow us to get it right first time. We control waste mitigation through design. Working SMART increases productivity and reduces hours on site. Finally, we delight our customer by being a trusted partner, understanding and achieving client specific solutions, accepting nothing less than excellence as standard, nurturing client collaboration across all platforms, responsive post contract service, digital commissioning & handover packs, and programme
At Ardmac we work ‘Smart’, meaning we deploy innovative technology throughout our business to empower our people, drive performance and delight our customers. We place our customer at the centre and apply Lean construction principles and technology to everything we do at Ardmac. We analyse problems through a structured innovation process and apply technology to solve them in a focused manner. Technology has the power to drastically change the face of the construction sector and Ardmac are committed to staying ahead of the curve.
Empower our People
Delight our Customer
Drive Performance
Deploying innovative technology throughout Ardmac to empower our people, drive performance and delight our customers.
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Potential BIM Lifecycle Participants
Laser Scanning, Set-Out & Construction Verification We understand the precision required in modern construction projects. To achieve this precision we are constantly innovating our construction processes. We have tested using laser set-out scanners on our projects to have exact set-out locations for our scope of work. We are also using laser scanners to verify our installation and generate a realtime report for the client to compare between design and as built elements.
BIM
FACILITY MANAGERS
SUSTAINABILITY MANAGERS
Ardmac is BIM Level 2 prepared and certified by BRE against ISO 19650 standards and BRE global BIM scheme requirements.
BIM/CAD TECHNICIANS
SPECIALIST CONTRACTORS
BIM MODELS & DATA
These techniques allow us to produce a clash free package saving time and re-work for everyone.
This certificate is designed to be used with contract forms, supplier’s pre-qualification questionnaires (PQQs) and to demonstrate Information Management (e.g. BIM Maturity) understanding and capability to clients and contractors.
MAINTENANCE TECHNICIANS
ENGINEERING CONSULTANTS
ARCHITECTS
It allows Ardmac to continuously exceed the appropriate standards and helps to provide the highest level of service to our clients.
3D Modelling
Ardmac understands the significance of creating and maintaining a digital twin of our construction projects to ensure better construction and maintenance. To ensure this we deploy best industry standard software. 3D modelling in BIM allows us to work collaboratively with different contractors within the cloud, allowing everyone to check for clashes and discrepancies between different services. This practice allows clients to see and evaluate a digital twin of their project even before construction starts and, hence allowing more flexibility.
Construction On site
We are constantly upgrading our site infrastructure and making our site teams BIM literate with inhouse and external training. We believe that the site team should have easy and open access to the BIM models and data to be a part of the whole construction process from start to end. We deploy a variety of platforms depending on the use case, for example model viewers on iPad or on site BIM stations. We also conduct site team workshop for software such as Navisworks and BIM 360.
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NISSAN CASE STUDY
4D Construction Ardmac have deployed 4D workflow on some projects to provide clients with more realistic modelling information that aligns with the programme and schedule of works. . 4D construction allows Ardmac construction team and everyone involved in the project to have a clearer understanding of the construction sequence including staging. When used collaboratively it helps everyone involvedin the project to identify errors in the construction plan and optimise the construction sequence.
Nissan, Sunderland, UK The UK’s first car battery manufacturing facility
Ardmac installed over 10,000m2 of sandwich panels. Architectural scope included partitions and ceilings (some fire rated), doors (various types), windows, interlocks, fire stopping, handrails and accessories along with process equipment enclosures. Ardmac installed the architectural fabric to maintain the controlled environment. Very low humidity areas necessitated the panelling system to act as a vapour barrier.
Air loss through conveyor openings was overcome by the introduction of rapid roller doors. This interfaced with the conveyor to open and close for the minimum time to allow product to pads through the wall.
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Enda Murphy MD Clean Rooms
enda.murphy@ardmac.com +353 85 8888340
Dermot McKenna Associate Director Business Development
dermot.mckenna@ardmac.com +353 86 8135475
Ardmac Ltd. Swords Business Campus, Swords, Dublin, Ireland K67 Y2P7
+353 (0) 1 8948800 info@ardmac.com www.ardmac.com
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