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Confidential Medical Manufacturing Client Plant Expansion

Gilbane delivered complex phased manufacturing plant additions on an active site where ongoing production without interruption is critical.

Delivering on an active Manufacturing Plant Site

The confidential projects consist of two phases. The first phase was a 125,000 SF renovation and upgrade of an existing production and warehouse facility. The project included a 60,000 SF addition to the existing facility that will house production process support and plant utilities to support the newly created space. The project created production capacity for FDA-regulated product manufacturing lines through process manufacturing equipment and piping, water for injection (WFI) systems, sterilization equipment, and other hygienic and plant utility infrastructure. This was a complex, segmented project that also included selective enabling work and demolition, site work, and other typical scopes of work for a project this size and type.

The second phase includes expansion to the production capacity with process upgrades, equipment, and renovations and additions to support spaces including labs, offices, loading docks, reclamation facility, and break rooms. Additionally, there is extensive site work to create additional parking, lift station, and underground utilities on the adjacent ten-acre site. This is a complex, phased project taking place within the active production facility. Co-location with the design team, safety planning, and enabling work is critical to meet the project needs and schedule.

Client Value

This project required an intensive coordination effort between Gilbane, owner, designers, MEP/FP/structural trade contractors and equipment vendors. The high density of future systems and tight equipment tolerances necessitated a laser scan of the existing building’s shell to verify existing column locations, walls, wall penetrations, precast embeds and slab edges. Using in-house modeling capabilities, the Virtual Design and Construction (VDC) team created a virtual representation of the as-built condition and future expansion by modeling new and existing walls, windows, doors, new and existing foundations, and clearances. VDC coordinated 160 different trade models, equipment models and necessary operational clearances.