Exyte Singapore's Safety Excellence in GlobalFoundries Singapore Expansion Facility Project

Safety excellence is non-negotiable in modern semiconductor construction. The GlobalFoundries Singapore Expansion Facility Project, managed by Exyte Singapore, sets a benchmark for safety excellence in high-tech construction. This project involved 23,000m² of cleanroom space, complex utility integration, and precision-driven installations — all executed under stringent safety protocols. 

Over 71,600 permits-to-work (PTW) and their subcategories were issued. The Work At Height category alone accounted for 32,000 permits, underscoring the high-risk, high-precision tasks integral to semiconductor construction. The Hubble Safety Management System allowed real-time permit tracking, hazard mitigation, and compliance with Singapore’s Ministry of Manpower (MOM) requirements — even during COVID-19 heightened safety periods. 

Outcome: 

• 71,600+ PTW applications processed efficiently. 
• Compliance at all stages, zero major incidents recorded. 
• Facility delivered ahead of industry safety benchmarks. 

The key insight is clear: investing in robust integrated digital safety management systems yields predictable operational results, even in complex, high-intensity semiconductor environments.

Introduction: Safety in Semiconductor Construction

Semiconductor facilities are precision-driven environments. Unlike generic construction projects, semiconductor fabrication plants demand cleanrooms with sub-micron particulate tolerances, intricate HVAC systems, and specialised utility installations. 

It is important to note that accidents in such environments do not only endanger personnel — they risk contaminating wafers worth millions of dollars, halting production lines, and triggering contractual penalties. 

According to Singapore Ministry of Manpower's Workplace Safety and Health Report 2022, construction remains one of the three most hazardous industries, accounting for 26% of workplace fatalities and major injuries in 2022. In semiconductor construction, the risk profile intensifies due to hazardous gases, ultra-clean spaces, and elevated work platforms.

Project Background: Exyte and GlobalFoundries

Exyte Singapore, a specialist in in designing and constructing high-tech facilities with over 30 years of track record in delivering successful projects in Singapore, is recognised for their precision in semiconductor, biotech, and pharmaceutical infrastructure projects.

At the other end of this dynamic partnership lies GlobalFoundries, a significant semiconductor manufacturer headquartered in the United States. As a major player in the semiconductor industry, GlobalFoundries is renowned for its proficiency in producing chips created by industry giants such as Qualcomm, MediaTek, and NXP Semiconductors. Their chips are utilised in numerous products, from smartphones and laptops to vehicles and AI systems.

In 2021, GlobalFoundries announced a US$4 billion expansion in Singapore to increase production by 450,000 wafers per year upon full operation (2025–2026). The expansion facility is part of Singapore’s plan to strengthen its advanced manufacturing sector, which contributed ~21% of GDP in 2023.

GlobalFoundries Expansion Fabrication Plant

This impressive collaboration is centred around the GlobalFoundries expansion fabrication plant in Singapore. This advanced facility covers an area of 23,000 square metres of cleanroom space and is a significant achievement in semiconductor manufacturing. Upon reaching its total capacity, expected sometime between 2025 and 2026, this state-of-the-art facility will produce an incredible 450,000 300-millimetre wafers yearly. Additionally, this expansion is expected to create around 1,000 high-value jobs, thus further improving Singapore's technological capabilities.

Safety Milestones: Managing Over 71,600 Permit-to-Work Applications

Exyte issued more than 71,600 Permit-to-Work (PTW) documents for the semiconductor construction project, ensuring rigorous safety compliance across diverse construction tasks. This figure highlights Exyte's unwavering commitment to careful planning and strict safety measures. 

The Parent Permit is a commonly used permit for the project, consisting of several subcategories such as Work At Height, Demolition, Hot Work, Confined Space, Work Above Clean Room Ceiling, Floor Opening/Raised Floor/Barricade Removal, Lifting Work, and more. The Work At Height Permit is the most prevalent among these subcategories, demonstrating Exyte's steadfast dedication to safety.

The construction of a semiconductor manufacturing facility is a highly intricate process, requiring meticulous planning, precise execution, and unwavering commitment to safety. At the core of this operation lies the management of various permits, with the Parent Permit being a linchpin. This permit encompasses diverse subcategories that encapsulate the multifaceted aspects of constructing a state-of-the-art facility.

Work At Height

Work At Height involves activities that soar above ground level, demanding skilled workers to install critical components with pinpoint accuracy. The construction of a semiconductor facility necessitates the installation of intricate systems at elevated positions, such as the precise placement of HVAC (Heating, Ventilation, and Air Conditioning) units and utility conduits. Each operation conducted at height requires stringent safety measures to safeguard the workers and the delicate equipment they handle.

For this project, the Work At Height Permit stands out as the most important among the various permits issued. Exyte Singapore has issued approximately 32,000 permit approvals in this category, reflecting their unwavering dedication to maintaining the highest safety standards for tasks performed at elevated locations throughout the project.

Demolition

Demolition is an indispensable phase, clearing the path for innovation by dismantling existing structures. In the context of a semiconductor expansion, outdated structures or facilities might need to be deconstructed to make room for cutting-edge installations. The careful removal of these structures is a precursor to the birth of a modern, technologically advanced semiconductor manufacturing facility.

Hot Work

Hot Work involves processes that utilise open flames or generate high temperatures. In the construction of a semiconductor facility, welding plays a pivotal role. The joining of metals through welding is crucial for structural integrity and the seamless integration of components. However, such operations must be conducted with utmost care and in adherence to stringent safety protocols due to the potential fire hazards associated with hot work.

Confined Space

Construction activities in confined spaces are an integral part of the semiconductor facility's development. These spaces, often limited in access and exit points, require specialised safety procedures. Tasks such as laying utility lines or installing equipment within confined areas demand meticulous planning and adherence to safety guidelines to ensure the well-being of workers.

Work Above Clean Room Ceiling

The clean room in a semiconductor facility demands an environment of exceptional purity. Work above the clean room ceiling involves tasks like installing specialised equipment or maintaining utilities. Any work in this area necessitates extreme care to prevent contamination, aligning with the stringent cleanliness requirements of semiconductor manufacturing.

Floor Opening/Raised Floor/Barricade Removal

Creating floor openings or modifying the raised floor is fundamental to accommodate equipment and utilities. Additionally, the removal or relocation of barricades facilitates the seamless movement of workers and materials within the facility. These alterations form the foundation for a dynamic and adaptable workspace, essential for the efficiency of the manufacturing process.

Lifting Work

Lifting work involves the strategic movement of heavy equipment and machinery, a critical aspect of constructing a semiconductor facility. From installing specialised machines to positioning substantial components, precise lifting is imperative for a smooth construction process. It's a delicate ballet of technology and strength, orchestrated to perfection.

Navigating through these complexities requires a systematic approach, meticulous planning, and the right safety measures in place. The Hubble Safety Management System, with its subcategories tailored to these critical aspects, empowers companies like Exyte to achieve safety and operational excellence throughout the construction phase.

Empowering Safety Through Hubble Safety Management System

Exyte Singapore's safety success story is deeply intertwined with the power of the Hubble Safety Management System. This advanced system has empowered Exyte to seamlessly navigate the intricacies of different work permits. Notably, it played a pivotal role in maintaining a safe worksite during the challenging times of the Covid-19 pandemic. The Hubble Safety Management System ensured compliance with Safe Management Measures (SMM) and facilitated a robust response during the heightened safety period (HSP). Moreover, it enabled Exyte to adapt swiftly to the ever-evolving safety guidelines set forth by the Ministry of Manpower (MOM), steering the GlobalFoundries Singapore expansion facility project towards sustainable Workplace Safety and Health (WSH) outcomes.

Project Completion: September 12, 2023

Despite construction during the COVID-19 pandemic, Exyte Singapore achieved milestone delivery within 12 months, highlighted by the movement of the first tool — a benchmark of progress in semiconductor facility readiness. The GlobalFoundries project reached full completion on 12 September 2023, overcoming supply chain instability and workforce limitations while maintaining a zero-majors-incident record.

Conclusion

Exyte Singapore's commitment to precision, innovation, and safety shines in their role in the GlobalFoundries Singapore Expansion Facility Project. Their meticulous use of the Hubble Safety Management System, notably in Work At Height Permits, sets new industry standards. Their impact extends beyond this project, serving as a beacon for the semiconductor industry, emphasising safety, innovation, and technology integration. Exyte Singapore is not just a participant but a guardian of excellence, shaping the future of semiconductor manufacturing. 

FAQ — Safety in Semiconductor Construction 

What makes semiconductor construction projects uniquely challenging in terms of safety? 

Semiconductor construction requires working in controlled cleanroom environments, handling sensitive equipment, and managing complex systems at height. The high precision and contamination risks necessitate specialised safety protocols, including permits for work above ceilings and confined spaces.​ 

How does the Hubble Safety Management System improve construction safety? 

Hubble digitises the Permit-to-Work process, streamlines safety checks, and ensures compliance with local regulations. This reduces paperwork, accelerates approvals, and provides real-time safety tracking, which is critical amid evolving safety requirements such as during the COVID-19 pandemic.​ 

Why is Work At Height the most common permit in this semiconductor construction project? 

A significant portion of semiconductor facility construction involves installing equipment and infrastructure at elevated positions. This includes HVAC units, piping, and electrical conduits. Risks are high due to fall hazards and equipment sensitivity, demanding meticulous safety controls.​ 

What are the key outcomes Exyte achieved through this semiconductor construction project? 

Exyte ensured over 71,600 PTW applications were managed efficiently, maintained a safe worksite during the pandemic, complied with MOM safety regulations, and helped GlobalFoundries meet tight project schedules, including moving the first tool within 12 months of groundbreaking.​ 

How can other organisations implement similar safety management improvements? 

Organisations can adopt digital safety management systems like Hubble to automate PTW processes and enhance risk visibility. Training programs aligned with these systems can embed a strong safety culture, leading to fewer incidents and improved compliance in complex projects.​

For organisations involved in semiconductor or other high-risk construction projects, leveraging digital permit-to-work systems is no longer optional but essential to ensure safety, compliance, and operational success. Request a demo of the Hubble Safety Management System to see how your construction projects can reach new safety and efficiency benchmarks.