This large and complex expansion of a biologic medicine manufacturing plant increased capacity 75% by adding three production bioreactors, each 15,400 liters, as well as associated seed reactors and expanded warehouse cold rooms, freezers and central utilities.

The team was challenged to execute the project in a live manufacturing environment, which added to the risks and complexity of the work. Crews installed and removed more than 1,000 large scaffolds in active work areas, most of which were tight spaces. The team developed a tagging system using cable ties on live services to ensure trades did not accidentally turn off any valve lever. They also had trades use acoustic cutting booths to eliminate risks.

Flexibility was key to mitigating the challenges of the aggressive schedule. Early planning helped the team identify risks and mitigate them. Trade partners worked double shifts and weekends to address worker density issues.

The team used 4D building information modeling to visualize progress through all stages of the project, using no paper at any stage. The digital approach carried over to turnover, and members of the team say it helped make construction a smooth and efficient process with a significant reduction in punch-list items.

With its completion, the facility is enabling the owner to pursue new solutions to advance medicine manufacturing for immunology and oncology.