Materials science is a rapidly growing field driven by the search for new materials to address a wide range of modern challenges—from developing safer, more efficient batteries to producing materials that meet the demands of quantum computing. Advancing this research requires spaces that accommodate sophisticated analytical equipment, ensure safety, and provide flexibility for future technological advancements.
However, the complexities of materials science labs often create challenges for designing the mechanical, electrical, and plumbing/piping (MEP) systems needed to perform research safely and effectively. Drawing on insights from Affiliated Engineers’ (AEI) experience renovating UL Research Institutes’ Materials Discovery Research Institute (MDRI) laboratory, the following discussion explores MEP design strategies to address the unique challenges associated with these intricate spaces.
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Resolving the climate control conundrum
Different materials science research demands varying levels of precision in temperature and humidity control. Some materials are susceptible to temperature fluctuations and require control within ±0.5°F. Achieving this level of precision involves detailed engineering, proper diffuser selection and placement, and often using computational fluid dynamics (CFD) to ensure stable conditions.
Additionally, specific analytical equipment requires process cooling for temperature control. For example, the MDRI houses equipment that relies on standalone process chillers, which presented AEI with a unique design obstacle. The chillers rejected heat in the room, and the insufficient air supply made it difficult to maintain proper cooling. As a result, MDRI required additional split-system cooling units to regulate the temperature effectively.
Managing the competition for ceiling space
A frequently overlooked design factor is the complex interplay of ceiling-mounted systems. Materials science labs often require a large network of supply and exhaust ducts to handle high air volumes, creating limited space above the ceiling. Components such as diffusers, sprinklers, lighting fixtures, occupancy sensors, overhead emergency showers, and gas detection systems compete for placement within the same 2’x2’ ceiling grid, requiring careful coordination to ensure optimal use of space.
Within the MDRI oven room, specifically, the intricacy of the required MEP systems posed potential challenges for installation during construction. The engineering team allowed the MEP systems to inform the room design and ceiling layout to ensure proper functionality, using early 3D modeling of the space to prevent costly conflicts during construction.
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Navigating utility system complexities
Gas management. Materials science labs typically utilize multiple specialized gases at varying pressures and purities. The MDRI’s design featured a centralized gas rack system to support various gases while maintaining strict safety protocols. Its design established dedicated zones for different gas types—inert, flammable, or oxidizing—to ensure proper separation and risk management.
To ensure gases could be added or changed as needed, the team routed gases below the ceiling on a pipe rack for easy identification and modification. However, accommodating a large number of gases led to a wider pipe rack, which introduced challenges for light and diffuser placement in the ceiling. Detailed coordination and analysis confirmed proper lighting levels and ventilation, ensuring a safe and functional laboratory environment.
Compressed air. Utility placement can significantly impact materials science laboratory design, yet it is often overlooked. Ideally, air compressors should be located outside the lab to minimize noise, vibration, and additional heat. If compressors are placed within the lab, the design must incorporate noise and vibration isolation systems while factoring heat gain into the final cooling requirements.
Pure water. Pure water demands within a materials science lab can vary, so including pre-treatment and point-of-use final treatment systems offers the most comprehensive design solution. This setup provides flexibility within the lab, and the point-of-use systems are easier to relocate as research needs evolve.
Closing equipment information gaps. One significant obstacle that laboratory designers and managers face is obtaining comprehensive technical information for analytical equipment. Effective lab design ultimately depends on having an accurate understanding of equipment specifications. However, the information manufacturers provide is often insufficient to fully assess MEP systems requirements. Essential details needed for MEP systems design typically include:
- Precise connection points (type, size, and location)
- Static pressure requirements for exhaust connections
- Heat output under various operating conditions
- Electrical requirements, including standby power consumption
- Control system integration parameters
Having access to a complete equipment list with comprehensive technical specifications can help accelerate the design process and ensure MEP systems are safe and compliant.
Other considerations for designing materials science labs
Take a holistic approach. Designing effective materials science laboratories necessitates a holistic approach that balances technical specifications, safety considerations, and operational flexibility. The complex interplay of systems within materials science laboratories necessitates close collaboration between laboratory managers, architects, and engineers throughout the design and construction process.
Integrate flexibility within the design. Flexibility is also important, as change is the one constant in material sciences. Analytical equipment and material testing requirements continue to evolve. Designing for a specific application on day one must also allow for future modifications to accommodate advances in technology and research needs.
Go beyond compliance when designing for safety. Maintaining a safe environment in materials science labs requires surpassing basic regulatory compliance. Lab design should ensure the integration of often-overlooked safety features, such as:
- Access control systems tailored to the hazard level, ensuring that only trained staff can access the lab
- Strategically placed safety showers, with careful attention to drainage requirements
- Water leak detection systems, particularly critical for protecting expensive analytical equipment
- Specialized monitoring for unique hazards associated with materials research
Planning, flexibility, and innovation are key
To support world-class materials science research, lab managers should keep these practical design takeaways in mind:
- Plan early with stakeholders to ensure MEP needs align with evolving research and equipment requirements.
- Use 3D modeling during design to visualize and resolve spatial conflicts in complex ceiling and utility layouts.
- Design for flexibility by using modular systems and adaptable utility routing that can evolve with research demands.
- Collaborate closely with engineers and architects to balance safety, technical performance, and future adaptability.
- Prioritize equipment data collection to prevent delays and ensure systems are sized and configured correctly.
- Go beyond code compliance by integrating safety systems tailored to specific lab hazards and materials.
- Anticipate future technologies by leaving room—physically and operationally—for expansion or upgrades.
