Polar Semiconductor is transforming its campus into a cutting-edge manufacturing hub to stand out in the global semiconductor market. With a strategic plan to increase output by 75%, Polar is expanding into compound semiconductors, sensors, and advanced technologies that power the future of automotive, industrial, green energy, and consumer electronics.
Modernizing a cleanroom facility while doubling capacity—without slowing production—demands precision and innovation. As Polar’s building partner, Mortenson is leading a highly complex renovation that touches nearly every part of the campus. Work includes constructing new cleanrooms next to active ones, upgrading aging infrastructure, and managing phased MEP tie-ins across multiple buildings—all while maintaining full manufacturing operations. Achieving this requires detailed sequencing, temporary utility reroutes, and advanced BIM coordination to execute major construction activities.
As one of the first recipients of the CHIPS Act, this project sets a benchmark for domestic semiconductor growth, helping to strengthen U.S. supply chain resilience and support national goals for technological independence and energy efficiency.
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Estimated Completion Date: August 2026
I am very pleased with the pace of activity. The project is a beehive of activity across the entire campus in a positive way.
Enabling Seamless Operations During Complex Renovations
Renovations to expand cleanroom areas are occurring adjacent to active cleanroom fabrication areas, where manufacturing is continuing at 100% capacity. As phased areas are completed, Polar continues to bring additional capacity online throughout the facility. Mortenson’s early engagement and strategic planning enabled construction to proceed without disrupting production—a feat that required detailed phasing, real-time coordination, and zero tolerance for downtime.
To support uninterrupted operations, Mortenson created temporary solutions for utilities—including gas piping, deionized water, heating water, chilled water, process water, and electrical systems—while permanent systems were being installed. These temporary solutions were developed in close collaboration with the mechanical, plumbing, and electrical trade partner and Polar’s facilities team, ensuring seamless transitions and allowing tools to come online ahead of final system completion.
Navigating Aging Infrastructure & Stacked MEP Systems
Built in 1969, the original building has experienced decades of system upgrades and reconfigurations as Polar continued modernizing its operations. Existing MEP systems required extensive investigation to identify what was active versus what could be removed to make room for renovations. Infrastructure complexity was heightened by the critical need to maintain uninterrupted 24/7 manufacturing operations, so relocating existing systems required detailed as-builts, coordinating temporary reroutes to keep systems live, and careful planning to finalize new locations for permanent feeds.
Mortenson and Polar mapped active systems, developed detailed schedules, and incorporated innovative solutions to ensure smooth operations despite the complexity of the project.
Engineering Innovation
Constructing a new elevator adjacent to active cleanrooms posed a significant challenge. Mortenson excavated a 25-foot-deep pit for the structure which was surrounded on three sides by active cleanroom spaces. Driving piles was not an option due to vibration risks, so the team implemented a specialized non-vibration earth retention system to enable safe excavation and concrete placement. Through strategic planning and collaboration, Mortenson delivered a solution that improves operational efficiency for Polar.
Mortenson used point cloud laser scanning technology to capture three-dimensional data of active fab spaces, enabling the team to create an accurate model of the existing environment for exact measurements. This technology verifies the exact locations of current systems and piping, helping determine whether relocation is necessary or if new designs should be modeled around them. For example, the P1 building, where structural overhead clearances are limited, point cloud laser scanning enabled more detailed dimensional coordination. This facilitated the development of re-routing plans and ensured the final installation met Polar’s goals for the finished condition.
Collaboration with BWBR Architects focused on developing solutions to minimize impacts on Polar’s active space. For example, the team installed H-frame steel on the exterior of the existing precast, instead of a typical install on the backside. Installing on the existing side is highly unusual for precast work but, effectively prevented disruptions inside the building. This approach enabled ongoing operations within the facility while advancing project goals.
Powering the Precision of Tool Moves
This project has a strong focus on tool move coordination. Through its Advanced Manufacturing Group, Mortenson brings deep industry expertise to manage the complex logistics of moving, installing, and commissioning of tools. Each tool follows a custom tiered workflow that includes decommissioning, decontamination, utility upgrades, vendor coordination, and quality checks. To keep the process efficient, Mortenson uses pull planning to optimize resource loading and to identify areas with limited capacity, allowing work sequences to be adjusted as needed. Weekly work plans and collaborative planning meetings with Polar ensure alignment on scheduling and resourcing, driving toward a successful finish.
Community Impact Through Workforce Development
The facility’s expansion brings significant benefits to the local community. Mortenson’s team is committed to workforce development, focusing on and emphasizing the need for women in skilled trades on the project. The project is expected to create over 160 new manufacturing and construction jobs at Polar, with a positive ripple effect on local employment and economic growth. To achieve this, Polar will lead the Minnesota CHIPS Coalition Workforce Partnership, which focuses on building and strengthening workforce development programs throughout Minnesota.