Texas Silicon Wafer Plant Highlights TD’s Process Piping Expertise

GlobalWafers USA (GWA), a subsidiary of the Taiwan-based global semiconductor silicon wafer company, completed construction on a first-of-its-kind manufacturing plant in north Texas for production of 300-millimeter silicon wafers, with the first customer shipment occurring this spring. This plant is the largest facility of its kind in the country and will receive more than $400 million of U.S. CHIPS and Science Act funding to revitalize domestic manufacturing and strengthen the American supply chain. From October 2022 to 2025, TD’s Process Solutions team worked on the GWA project spanning more than 1.4 million square feet of its facility.

Design-Build Leadership

TD’s initial scope was to design-build the facility’s compressed air plant. The plant includes two oil-free 3-stage turbo centrifugal compressors, one oil-free rotary screw compressor and three heated blower-type desiccant dryers, each weighing between 6,000 and 21,000 lbs. TD’s engineering and process piping teams coordinated equipment placement using virtual design construction (VDC).

These models were created with close collaboration between process, mechanical, structural, architectural and various other engineers as well as multiple subcontractors working together on the Central Utility Plant (CUP). This project required extensive communication between all stakeholders, which required multiple design calls each week to ensure a unified approach. “You can really see just how accurate those VDC models are to the finished project,” says TD Senior Mechanical Designer Jacob Featherston.

TD’s engineering team includes employee-owners Fred Henke, Jeff Farley and Featherston, who are credited with the initial contract that led to an expanded scope carried by TD’s process piping construction team. GWA’s engineering team on record was happy to have help with their initial load. “We were able to fill that gap,” says Henke.

The process piping construction and Plano, Texas, prefabrication teams supported the project through completion. Various systems were shipped in pieces, also called spools, to be installed on-site, where the process piping team helped assemble and complete a critical project milestone. This cohesive coordination allowed TD to deliver on tight deadlines and complete all prefab work in the agreed-upon six weeks.

Project Scope

The complete project scope involves piping and process systems work in five production categories: specialty gases, chemicals, slurry, bulk gases and compressed dry air (CDA). In addition to piping, TD worked with GWA and manufacturers to procure and install equipment for the base build systems. All aspects are part of the intricate and detailed process to create a perfect, sterile surface for the customer to build the finished wafer product.

Silicon wafers are used as a substrate, or surface, for producing semiconductors or electronic components used in most microchips, microprocessors and sensors in electronic devices. Their high-purity, uniformity and smooth surface make them a main element in integrated circuits.

TD’s team used VDC to model 36,000 linear feet of stainless-steel pipe and tubing for the specialty gases, bulk gases and CDA. The primary role of CDA within this massive plant is valve actuation and automation of controlled processing tools. Additionally, TD also installed 34,000 linear feet of PVC and polypropylene piping for chemicals and slurries. Using 10 to 15 types of materials, TD has helped procure and install piping throughout the project’s phases.

Due to the high risk of this facility’s chemicals and specialty gases known as Hazardous Production Materials (HPM), these systems required dual containment of an inner carrier tubing that is installed, pressure tested and vacuum-leak tested before proceeding with the welding of the outer containment. For chemical distribution, the team began by installing the heat bent schedule 40 PVC outer containment with precision to place low points in very particular spaces that would be accessible should a leak occur. When the outer containment was complete and tested, Perfluoroalkoxy (PFA) tubing was pulled through this containment to create as little mechanical connections throughout the system as possible.

The TD team, coordinating with GWA and Engineer of Record requirements, procured and installed compressors, purifiers, gas equipment and chemical distribution cabinets. TD provided a turnkey process mechanical installation of building systems including process drains, process exhaust and pneumatics.
These methods of installation are common within the semiconductor industry to maintain the health and safety of all parties working within a factory. Without missing deadlines, TD’s team overcame procurement and supply chain hurdles, while adhering to additional safety requirements.

Bulk Gas Installation

TD used skids to transport complex bulk gas systems weighing up to 12,000 lbs. that were prefabricated in TD’s off-site manufacturing facility. TD coordinated transportation and rigging of the systems for installation from the gas yard through the gas purification room.

This level of detail is a testament to the planning and coordination between the VDC, prefabrication and construction production and operations teams executing the project on-site.

Community Impact

With most global production in Asia, this plant has huge implications in strengthening U.S. status as a silicon wafer manufacturer. Silicon wafers from this facility will be used in manufacturing advanced leading-edge and memory devices, along with a dedicated section for silicon epitaxy wafers, a critical component in high-voltage applications, including electric vehicles and clean energy infrastructure.

Combined with the expansions of GlobiTech and Texas Instruments manufacturing plants, Sherman and north Texas communities, these facilities are estimated to add 7,000 jobs to the economy. After completing production of the first 300-mm-sized wafer on Dec. 30, 2024, TD completed installation through the project completion date in May 2025.