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Pharmaceutical Client | Autoclave Addition

Autoclave Addition

Eastern PA


Pharmaceutical Client
Eastern, PA

Design Professional

Vestal, NY



L.R. Costanzo expanded this manufacturer’s sterilization capabilities by constructing a new addition to support two new GMP autoclaves. This project also included upgrades to process utilities and new mechanical equipment to support the new autoclaves.


  • Complete tie-ins into the existing operating production areas
  • Fast-track work schedule
  • Minimal lay-down / staging areas
  • Building located on severely sloped site
  • Shoring and underpinning of the existing building’s foundation system
  • Existing underground utilities conflicting with new foundation and structure


  • Constructed FDA approved, cleanable, temporary partitions during shutdown period to allow a smooth integration of the production spaces at construction completion
  • Careful coordination and scheduling with building users to schedule clean and building utility tie-ins and other critical work
  • Air freight and customs expediting for sterilizers to maintain fast track schedule
  • Rerouted pedestrian traffic to allow for safe construction site and additional staging areas
  • Installed massive deep foundations and oversized steel structure to keep addition separate from the existing building structure
  • Installed temporary systems and measures to enable shutdowns of utilities to allow re-routing


L.R. Costanzo experts also installed:

  • 3200 pound clean steam generator
  • Installation of two large GMP sterilizers
  • Clean steam and DI water system piping
  • New mechanical system upgrades for the new addition included a GMP air handling unit, exhaust fans, heat exchangers, and new chilled water system from the new on-site central utility plant
  • Class 100 laminar flow system (entire ceiling)
  • Upgrades to DI water system
  • New propane supply tank and piping
  • Re-piping of the existing phenol waste tank conflicting with new structure
  • Commissioning and validation support of new autoclaves and process systems