Client Project 3

Client 3 faced one of the most disruptive contamination risks in legacy raised-floor environments: zinc whiskers. It’s often debated because only a small percentage of facilities are impacted—but when it happens in your site, it becomes immediately obvious through real-world operational failures and escalating risk.

The Facility Layout

• Approximately 3,000 sq. ft. total
• Three separate rooms connected by shared underfloor airflow distribution beneath the raised access floor (RAF)
• A design that can allow particulate contamination to migrate across spaces if not controlled quickly and correctly

The Trigger: Once Identified, Everything Accelerated

After zinc whiskers were confirmed, multiple issues began hitting at once:

• Server power supplies failing and increased hardware instability
• Vendors refusing to install new equipment due to contamination risk
• Insurance pressure for documented contamination control and corrective action
• A clear requirement emerging: full replacement of the raised access floor system, not patchwork fixes

Because the client was a pharmaceutical manufacturing company, time-to-resolution was critical. Any extended disruption posed a risk to production continuity, compliance expectations, and operational confidence.

Our Response: Rapid Coordination + Controlled Procedures

We moved quickly with a plan built around speed, control, and verification:

• Held rapid-response stakeholder meetings to align priorities, responsibilities, and sequencing
• Implemented clear methods and procedures for contamination containment, cleaning, and controlled work zones
• Executed a coordinated scope to clean, seal, and replace the RAF system while protecting adjacent operations and critical infrastructure

Result: Cleaned, Sealed, and Replaced in Less Than 4 Weeks

The facility’s impacted areas were cleaned, sealed, and the raised access floor system replaced in under four weeks—restoring vendor confidence, reducing contamination risk, and enabling the site to move forward with stability and compliance-driven operations.