Project Overview

This fast-track project included three distinct scopes under one initiative: renovation of 12,000 SF of existing lab space, fit-out of a 10,000 SF warm shell on the first floor, and a 5,000 SF second-floor office-to-lab conversion. Each component served different lab functions, but all required high-reliability power systems, precise equipment coordination, and meticulous field verification to support ongoing operations and future growth.

Role & Responsibilities

Power & Emergency Systems – Designed temporary and permanent UPS and generator power distribution systems, including salvaged 300kVA and future 400kVA UPS integration, as well as dual 600kW generators with paralleling gear.
Lab Equipment Relocation Infrastructure – Conducted field surveys across multiple sites to build a lab equipment list of over 100 pieces. Designed custom branch circuit relocation and data network connections to support user-specific layouts.
Electrical Service Upgrades – Converted from a switchboard-metered to a transformer-metered service to overcome space constraints and enable additional power distribution within existing rooms.
Temporary Construction Power & Cutover Sequencing – Engineered a temporary generator hookup with transfer coordination to protect active cold storage and mitigate risk during the construction transition.
Vendor & Trade Coordination – Led extensive coordination with the owner’s vendors and electrical contractors, including dimensional field verification and tailored equipment fit-out in space-constrained rooms.
Documentation & Permitting – Delivered a permit-ready set in under four months despite slow information flow. Issued detailed documents that incorporated assumptions, owner risks, and forward-looking scalability.

Key Challenges & Solutions

🔹 Unknown and undocumented existing lab equipment to be reused in the new design
✔ Solution: Personally visited all offsite locations to identify, photograph, and catalog over 100 pieces of equipment. Used this database to drive design decisions for power and network connections.

🔹 Delayed delivery of planned 400kVA UPS unit, creating potential schedule and operations risk
✔ Solution: Sourced and commissioned a salvaged 300kVA UPS from another facility. Designed the infrastructure to accommodate both units and allow seamless cutover once the new unit arrived.

🔹 Long lead time for generator equipment threatened project schedule
✔ Solution: Replaced single 1250kW generator with two 600kW units and paralleling gear. This met performance needs while avoiding delay due to equipment availability.

🔹 Electrical room constraints made it nearly impossible to fit new gear
✔ Solution: Sourced minimum-footprint gear, performed field verification of every dimension, and coordinated door hardware modifications to meet NEC clearance requirements.

🔹 Existing electrical service type could not support expanded distribution within space limits
✔ Solution: Converted service from switchboard-metered to transformer-metered, enabling more compact distribution layout without expanding the electrical room footprint.

🔹 Risk of cold storage equipment failure during power transitions
✔ Solution: Designed temporary generator hook-up to protect critical systems during construction cutover, reducing operational risk for current lab tenants.

🔹 Compressed design schedule with slow information flow and changing inputs
✔ Solution: Made defensible assumptions, documented all gaps, and built flexibility into the design to enable continued forward progress without sacrificing quality or compliance.

Outcome & Impact

✅ Dual-path UPS and generator systems – Enabled critical lab and cold storage equipment to remain operational across all construction phases and power conditions.
✅ Resilient design under tight timelines – Leveraged temporary systems and vendor coordination to meet aggressive occupancy goals.
✅ Precision fit-out and coordination – Avoided construction delays by validating dimensions and matching distribution gear to physical constraints.
✅ Scalable future-ready systems – UPS and generator infrastructure designed for cutover flexibility and future lab expansion.
✅ Risk-informed execution – Assumptions were documented and de-risked, allowing the owner to move forward with confidence.

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Lab infrastructure isn’t just technical—it’s tactical. If your team needs a design partner that handles complexity without slowing down the mission, we’re ready to help.

Multi-Phase Lab Renovation & Fit-Out — Confidential Biotech Client