Innovative Construction & Assembly Strategies
Insights on cGMP Pharma Manufacturing Facilities
Introduction
Project Endeavor, located in Frederick, Colorado, involves a 215,200 sq. ft. ground-up addition to an existing pharmaceutical manufacturing facility.
This expansion includes a 172,000 sq. ft. manufacturing lab, a 31,500 sq. ft. central utility plant (CUP) and warehouse expansion, and an 11,700 sq. ft. tank farm.
The cGMP (Current Good Manufacturing Practices) space is designed to produce bulk active pharmaceutical ingredients (APIs) in accordance with Process Safety Management (PSM) standards
By incorporating prefabrication, modular concepts, and innovative materials, the team developed a robust field assembly strategy that prioritized efficiency, quality, and adaptability.
Robust Field Assembly Strategy
To maximize fabrication and installation efficiencies, the project team adopted innovative methods involving prefabricated piping and modular solutions.
These components, including prefabricated process piping (not including mechanical piping, HVAC or plumbing) and equipment skids, were fabricated offsite in California and then brought into the building.
This strategy minimized construction site clutter and “stacking” of Trades while supporting the project schedule and reducing onsite labor constraints by an
estimated 40% for certain packages. This multifacted project involved 70 contracts covering a wide variety of disciplines and trades.
Advanced Clean Room Technology
The project also incorporates advanced clean room technology, utilizing modular, fire-rated clean room panels imported from Europe. These panels, the first of their kind in the U.S., are designed to withstand the rigorous demands of the project’s chemical processes.
Measuring 5 feet by 17 1/2 feet, the panels underwent extensive testing for chemical resistance to ensure they maintained their integrity and performance in the controlled environment.
