Collaboration through Stringent Processes
Confidential Life Sciences Client | Louisville cGMP Warehouse | Louisville, CO
DPR and the client formed a collaborative partnership as they built new cGMP warehouse space next door to sensitive manufacturing lines, applying strict environmental controls typically used in active healthcare facility construction.
About The Project
This project created cGMP warehouse space inside an existing manufacturing facility. The scope of work included a soft demo of existing rooms, early procurement of MEP trade partners onboarded by DPR as design-build, construction of a cold room, epoxy flooring, high-bay storage, replacement and retrofit of overhead coiling doors and a new airlock. A new catwalk system was also constructed above occupied manufacturing space to provide the client with convenient access to overhead mechanical systems.
Infection Control Risk Assessment (ICRA)
While the project’s construction area was shelled space, manufacturing space was adjacent to the construction area, and all the facility’s critical MEP systems ran directly through it.
Aligning to the project’s need for strict environmental controls, several Infection Control Risk Assessment (ICRA) containment measures were put in place to isolate the construction area from the client's personnel and sensitive manufacturing equipment. A standard for construction projects in active healthcare facilities, the ICRA process identifies and reduces the risks of spreading airborne or waterborne pathogens.
Photo Credits: Fred J. Fuhrmeister
Method of Procedure (MOP) Protocols
The client's facility and its production schedule were placed at the center of importance for this active manufacturing facility project. Method of Procedure (MOP) protocols were established and continually developed throughout the project between the client and DPR. This was a detailed way to collaborate and provided a structured process for operating in the client's active facility. MOPs were respected, requiring schedule adaptations or off-hours and weekend work.
Photo Credits: Fred J. Fuhrmeister
Collaboration
Both DPR and the client are extremely collaborative partners in the construction process. Even with modern work culture shifts to be more virtual, In-person meetings were preferred by both teams, and the client and DPR prioritized frequent walks of the construction site together. DPR and the client's project offices were located next to one another, improving efficiencies in communication and decision making throughout the project.
Photo Credits: Fred J. Fuhrmeister
Catwalk Construction Above an Active Manufacturing Space
The client sought to improve ease of access to overhead mechanical, electrical and plumbing (MEP) systems above an existing manufacturing cleanroom and turned to DPR for the ideal solution. To inform the new catwalk system, the project team completed a point cloud scan of the mezzanine level where the MEP systems resided. DPR worked to avoid any design decisions that would require the catwalk structure to reach the active manufacturing space floor below. The team went through several design iterations with active involvement from the client's facilities team to refine the catwalk solution.
After careful consideration, the project team chose a misc. metals solution which avoided any structural tie-in support from the manufacturing space below. Our project team worked hand in hand with DPR self-perform Misc. Metals team, completing the catwalk without any stop-work issues or damage to the facility.
Photo Credits: Fred J. Fuhrmeister
Catwalk Construction Above an Active Manufacturing Space
The client sought to improve ease of access to overhead mechanical, electrical and plumbing (MEP) systems above an existing manufacturing cleanroom and turned to DPR for the ideal solution. To inform the new catwalk system, the project team completed a point cloud scan of the mezzanine level where the MEP systems resided. DPR worked to avoid any design decisions that would require the catwalk structure to reach the active manufacturing space floor below. The team went through several design iterations with active involvement from the client's facilities team to refine the catwalk solution.
After careful consideration, the project team chose a misc. metals solution which avoided any structural tie-in support from the manufacturing space below. Our project team worked hand in hand with DPR self-perform Misc. Metals team, completing the catwalk without any stop-work issues or damage to the facility.
Photo Credits: Fred J. Fuhrmeister
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