Illuminate USA

Designed and built for Illuminate USA, this project is a 1,100,000-total-square-foot 5GW mono-crystalline solar manufacturing facility.

This 1.1M SF mono-crystalline solar manufacturing facility is a cutting-edge production hub designed to meet significant global demand for renewable energy solutions. Built within an existing speculative structure, the project integrates state-of-the-art systems and infrastructure to enable 5GW of mono-crystalline solar manufacturing annually.

Key facility spaces include specialized areas such as a laboratory, mezzanine, cleanroom, packaging room, warehouse, mechanical room, conference rooms, break rooms, and a kitchen. The production floor is the centerpiece, featuring 600,000 SF of solar manufacturing equipment and a 12,000 SF destructive testing lab. Additional components include a hazardous materials warehouse and a robust 34.5 kV medium-voltage electrical system.

The facility supports industrial-scale operations with 3200 HP compressors, 660 tons of closed-loop process cooling water systems, and an extensive 30MW+ power distribution network. A regenerative thermal oxidizer ensures effective soldering exhaust gas filtration, prioritizing environmental safety and compliance. Plant-wide utility upgrades cover water, sewer, natural gas, and electrical systems, while lighting and ventilation systems have been optimized to support operations.

With 3,000 tons of cooling load to mitigate heat output from equipment, the project also includes comprehensive process mechanical installation—covering piping, ventilation, and ducting systems.

Delivered through a full design-build package, the project encompassed preconstruction services such as architectural design, engineering, and permitting, ensuring a seamless transition from concept to execution. This advanced manufacturing facility underscores a commitment to renewable energy, technical precision, and sustainability.