U.S. Customs Facility HVAC - Waukegan National Airport

EOS Mechanical provided complete HVAC systems for the U.S. Department of Homeland Security’s new Customs and Border Protection facility at Waukegan National Airport—delivering reliable climate control supporting federal inspection operations while navigating supply chain challenges and evolving security requirements.

About the Facility

Waukegan National Airport serves as a reliever airport for Chicago’s congested airspace, accommodating general aviation and business aircraft operations. The new U.S. Customs and Border Protection facility enables international arrivals to clear customs locally rather than diverting to major airports, enhancing aviation services for the northern Illinois region.

The federal facility houses customs inspection operations, requiring reliable HVAC systems supporting year-round operations regardless of weather conditions. Building systems must maintain precise environmental conditions for electronic inspection equipment, personnel comfort, and operational readiness.

As a federal Homeland Security facility, the project required compliance with stringent government construction standards, security protocols, and operational continuity requirements—including emergency backup systems not originally in the project scope.

EOS Mechanical Scope

EOS Mechanical provided turnkey HVAC installation including equipment, distribution systems, controls, and gas piping infrastructure supporting building operations and emergency backup systems.

Air Handling & Climate Control

• Trane rooftop unit - High-efficiency packaged equipment
  • Integrated Tracer Concierge wireless controls
  • Matched capacity for facility loads
  • Energy-efficient operation with variable speed capability
  • Factory-assembled and tested for reliability
• Split systems - Supplemental cooling for specific zones
  • Dedicated cooling for equipment rooms
  • Flexibility for varying thermal loads
  • Independent zone control

Ventilation & Air Quality

• Exhaust fans - Building pressurization and air quality management
  • Continuous ventilation meeting federal facility standards
  • Coordinated with supply air systems
  • Reliable operation for year-round use
• Electric wall heaters - Perimeter heating for comfort
  • Supplemental heating for entry areas
  • Quick response for occasional use spaces
  • Simple, reliable technology

Advanced Wireless Controls

• Trane Tracer Concierge system - Wireless building automation
  • Wireless thermostats eliminating hardwired controls
  • Direct communication between VAV boxes and rooftop unit
  • Simplified installation and commissioning
  • User-friendly interface for facilities management
  • Remote monitoring and diagnostics

Infrastructure & Emergency Systems

• Gas piping distribution - Serving multiple building systems
  • Rooftop unit fuel supply
  • Standby generator fuel connection
  • Emergency backup capability
  • Coordination with electrical systems for generator integration

Construction Challenges & Solutions

Challenge: New Wireless Controls Technology

The project specified Trane’s Tracer Concierge system—an advanced wireless BAS platform eliminating conventional hardwired control wiring. While offering significant installation advantages, this technology represented new territory for our team, requiring specific knowledge for proper setup, commissioning, and long-term reliability.

Our Solution: Proactive Training and Certification

Rather than learning on the job and risking schedule delays or performance issues, EOS Mechanical took a technology-forward approach:

1. Pre-Installation Training

   • Enrolled team in Trane’s virtual training program before mobilization
   • Obtained manufacturer certification in Tracer Concierge technology
   • Practiced setup and commissioning procedures
   • Developed internal installation standards

2. Execution Benefits

   • Installed and commissioned the system correctly on first attempt
   • No learning-curve delays during critical installation windows
   • Confident troubleshooting of any installation issues
   • Professional customer training on system management

3. Long-Term Value

   • Added wireless BAS capability to EOS service offerings
   • Created repeatable processes for future projects
   • Built manufacturer relationship for technical support
   • Positioned company for emerging control technologies

This investment in training protected the project schedule while expanding our technical capabilities for future work.

Challenge: COVID-19 Supply Chain Disruptions

During 2021, the pandemic created unprecedented supply chain volatility. Specialty HVAC equipment and controls experienced unpredictable lead times, threatening project schedules. Traditional just-in-time procurement carried unacceptable risk for a federal facility with firm operational deadlines.

Our Solution: Strategic Pre-Ordering and Inventory Management

EOS Mechanical made an early strategic decision to pre-order and warehouse all specialty items:

1. Proactive Procurement

   • Identified all long-lead and specialty items early
   • Ordered critical equipment at project start
   • Purchased items ahead of actual need dates
   • Accepted capital investment to protect schedule

2. Controlled Storage

   • Stored equipment at our fabrication facility
   • Maintained environmental protection during storage
   • Managed inventory throughout project duration
   • Delivered materials using our personnel on our schedule

3. Risk Mitigation

   • Eliminated exposure to supply chain uncertainties
   • Protected critical path schedule
   • Enabled flexibility in field installation sequencing
   • Maintained control over equipment availability

This approach required upfront capital but protected Homeland Security’s operational timeline—demonstrating commitment to client mission over short-term cost optimization.

Challenge: Mid-Project Security Requirement Changes

Midway through construction, the U.S. Department of Homeland Security updated their facility security doctrine, mandating emergency backup capabilities not included in original project scope. These requirements emerged after equipment procurement and installation planning were complete.

Our Solution: Accelerated Mobilization and Scope Adaptation

When new requirements became clear, EOS Mechanical responded with exceptional flexibility:

1. Early Mobilization

   • Mobilized to site several weeks ahead of planned schedule
   • Reshuffled workforce across multiple concurrent projects
   • Prioritized equipment and materials for expedited delivery
   • Coordinated with electrical contractor for generator integration

2. Scope Integration

   • Installed additional gas piping supporting backup generator
   • Modified HVAC connections for emergency power compatibility
   • Integrated controls for automatic emergency mode operation
   • Ensured all systems functioned on generator backup

3. Schedule Protection

   • Absorbed scope changes without extending completion date
   • Maintained original project timeline despite added work
   • Protected Homeland Security’s operational readiness date
   • Demonstrated flexibility essential for federal facility work

This adaptability required significant internal coordination and resource reallocation, but it ensured the federal facility met evolving security requirements without schedule impacts.

Federal Facility Requirements

Working for the U.S. Department of Homeland Security required compliance with stringent federal standards:

Quality & Documentation

• Installation per federal specifications
• Complete submittals and O&M documentation
• Manufacturer-certified startup and commissioning
• Training for federal facilities personnel
• As-built drawings reflecting actual installation

Operational Readiness

• Integration with emergency power systems
• Backup capability for all critical systems
• Reliable year-round HVAC operation
• Simple, maintainable technology choices
• Remote monitoring for federal facilities management

Results

The completed HVAC installation provides:

• Reliable climate control supporting customs inspection operations
• Modern wireless controls simplifying facilities management
• Emergency backup capability meeting security requirements
• Full integration with standby power systems
• Flexible system configuration for varying operational needs
• Project delivered on schedule despite supply chain challenges and scope changes
• Federal facility operational readiness achieved per Homeland Security requirements

This project demonstrates EOS Mechanical’s adaptability to emerging technologies, proactive risk management, and flexibility responding to changing requirements—all critical capabilities when executing federal facility work. Our investment in training, strategic procurement, and rapid response to evolving scope enabled Homeland Security to activate this customs facility on schedule, enhancing aviation services for northern Illinois while meeting stringent security requirements.