Pharmaceutical Client | Autoclave Addition
Autoclave Addition
Eastern PA
Owner
Pharmaceutical Client
Eastern, PA
Design Professional
Sear-Brown
Vestal, NY
PROJECT
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.
CHALLENGES
- 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
SOLUTIONS
- 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
CONSTRUCTION DETAILS
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