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DuPont's Bellevue Road campus in Newark, Delaware recently added a 350,000-square-foot warehouse designed to support their product line expansion to help meet growing semiconductor chip demand. Sitting in a storage containment is specialized equipment waiting to be installed in time for 2026 operations. Creating and maintaining constant climate conditions for the unit is critical to the success of the project.
The equipment carries a 2-year lead time and needs to be stored in less than 40% relative humidity to prevent rust and surface buildup. Any damage incurred during the storage period would be at the owner’s expense. Having worked with Polygon for many years, DuPont’s Project Team Leader, Roseann Blount, enlisted our team to help produce a temporary microclimate to protect their investment.
The project posed several challenges due to the scale and nature of the facility. The building was completely un-climatized leaving it vulnerable to external temperature fluctuations that directly affected the containment space. Traffic from personnel and equipment moving in and out was expected to cause temperature and humidity fluctuations. And outside seasonal changes, particularly during the summer, were likely to exacerbate humidity issues, adding yet another layer of complexity.
To solve this Polygon implemented a proactive phased approach that included a mix of real-time sensors and climate equipment. During early winter months, operation technicians installed four ExactAire Multi Sensors at the corners of the containment space to monitor temperature and humidity. They also hooked up one HC-600 dehumidifier to maintain 40% RH.
As humidity level rose during summer months, data informed the team when to add a second dehumidifier. Waiting to install the extra equipment minimized service and energy costs without compromising overall conditions.
Everyone was able to actively monitor the space via dashboards and alerts. When humidity fluctuations were observed, Polygon would call the DuPont onsite team who were able to investigate or report non-emergencies like scheduled building power shutdowns or high-traffic days.
“DuPont values partnerships with vendors who show the same respect to their clients that we strive to provide. This is why working with Polygon has been such a positive experience,” said Blount.
“The data alerts gave us an added layer of protection,” said Blount. During a rainstorm approximately 5 inches of water fell in under 6 hours. “Humidity was skyrocketing, and we thought: did the equipment break down, did someone unplug it?” shared Blount. “No, we had a storm, and a little water entered the space leaving minor puddles. The sensors picked up on it, notified the onsite team who checked it out and deemed it a non-emergency. The dehumidifiers leveled everything out.” Without the Polygon system in place, the issue might have gone undetected for longer, as routine visual checks are conducted biweekly.
Responsiveness – Polygon rapidly designed and installed a system, provided active oversight of conditions remotely, and supported the onsite team throughout the project, making for a seamless solution.
Constant conditions – Continuous monitoring and control provided the protection and confidence the project team needed to safeguard their investment until installation.
Risk mitigation – Polygon digital sensors and instant alerts provided DuPont with actionable insights into the containment space's conditions giving them information when they need it to mitigate risk swiftly.
The success of the project has inspired the Polygon and DuPont teams to apply this same technology to other parts of the campus. In 2025, a temporary climate control solution will be designed to protect semiconductor materials in storage. For more information on Polygon monitoring and climate control solutions visit, www.polygongroup.us/services.
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