Chicago-Area Industrial Spaces Looking for off-site assembly spaces

2 Off-Site Assembly space Under discussion Assemble the warm vessel elsewhere, before we have access to the Far Detector building Assemble two halves which are too large for any existing building/doors at Fermilab Are there locations off-site which could serve? Requirements minimum of ~5000 sq-ft configured be at least 45-ft wide and 110-ft long ceiling height at least 30-ft clear Door 23-ft high and 18-ft wide We do not require a bridge crane we can rent a gantry to lift and position sections of the warm cryostat however these lifting actions will require some head-room thus the requirement on ceiling height If a bridge crane is available - then it needs ~25-30-ft hook height; 5-10 ton capacity Each fully assembled half-section would then be rolled out of the assembly area, and placed onto the transport vehicle parked outside, using a truck crane thus the requirement on door size The cost of transport must also be added to the cost estimate Do such spaces exist? 2

3 Typical Industrial Space The Chicago area, including the local Fermilab area, has many industrial buildings. However, their configuration is generally similar to the photo below. The main drawback for our needs is the size of the doors. They are sized for a standard U.S. freight truck, which is significantly smaller than the size of a half section of the warm cryostat. Buildings like this typically have several loading docks and one or two drive-in doors. Very few of these warehouse-style buildings have an overhead crane. This one does not. This particular one has 30-ft high interior ceilings – which is taller than most. There is space enough inside this local building (a few miles north of Fermilab) to assemble halves of the warm cryostat, but we would not be able to get the completed half-assembly out of the building! 3 Drive-in door Loading Docks

4 Another local example (St Charles) Here is another property in the local ready-to-lease listings. This one had some views of the interior. But note, in the bottom photo, the size of the door! The drive- in door is 14-ft tall and 12-ft wide. This space has 23-ft high ceilings, which is also marginal for us Spaces like this, and the one on the previous slide, would cost around $25,000-$40,000 for three months (varies by size and amenities)

5 Look familiar? This old factory is at the corner of Fabyan Parkway and Batavia Ave, just on the west side of the Fox River. You might have driven past it on your way to the grocery store. The high-bay space in this building has been used by Fermilab experiments once or twice in the past, as an assembly space. It has a bridge crane. But – as for most other buildings, the doors into the high bay are sized for ordinary trucks. Half of the warm vessel will not fit through the door.

6 Search the broader Chicago Area I spent a few hours with online listings, looking for properties which were different from standard warehouses, and located anywhere within 50 miles of Fermilab. This is not intended to be the only search effort. If we decide to pursue this option then more searching is needed. But this gives an idea of the sorts of spaces available for lease. The one pictured here looks nice and open. But the ceiling height is only 18-ft, and the drive-in door is 12-ft x 10-ft

7 Better candidate This one has overhead cranes! Three spaces are available (red boxes), two with 10-ton cranes, the other with a 30-ton and 10-ton crane. The hook height is 21-ft. 40-ft clear height Does not say how large the doors are – and unfortunately the photo shows “standard” looking doors. However, the brochure says loading is “expandable”, whatever that means. The spaces are large, more than we need. The cost for the smallest is about $45,000 for three months I am not sure however that they lease for less than a year – a year is $190,000!

8 Another Very high ceilings. Lots of space. No crane. No information on the doors, either. It is located in the middle of downtown Chicago, which would mean moving the assembled halves of the warm cryostat through Chicago city streets. Probably not a good option

9 Another, with cranes Has overhead cranes But doesn’t say how large the drive- in doors are They look standard. Meaning, too small

10 Cost estimate The old factory on slide 7 is the best candidate from this simple search. It is located 55 miles from Fermilab, on the south side of Chicago. A 1.5hr drive, according to Google Maps. Lease the space for 3 months ~$50,000 Moving costs we would need to spend a few days (and manpower) to move our tools and equipment from the Lab to this location, and back again. Est $10k Daily commute costs all technicians/welders will have to drive to/from this location This is likely to translate into inefficiencies in the workday (people start late because they get stuck in traffic… effective working hours are reduced) so the time to assemble each half may take longer than expected, which means more $ labor or we will spend $ on overtime labor in order to stay on schedule Est $20k Transport of the finished product the two completed halves must be transported the 55 miles back to Fermilab Wide load!! We will need to arrange special-permit transport Est $20k I see this option costing at least $100,000 more than the cost to assemble on-site at Fermilab

11 Summary Is it possible to find an off-site assembly space for the assembly of the warm cryostat? yes Advantages reduce default installation timeline by ~ 2 months Disadvantages higher cost. est $100k Conclusion this option is possible, but if I am going to spend $$ in order to reduce the installation timeline, then there are likely better ways to do so for example – spend a certain time period on double-shifts (16 work hours/day) on a focused portion of the installation. Not necessarily on the warm vessel assembly. Perhaps on portions of the cryogenics installation.