GMP PHARMACEUTICAL MANUFACTURING AND DRY PACKAGING FACILITY
DESIGN & BUILD FIT-OUT FOR GMP PHARMACEUTICAL MANUFACTURING AND DRY PACKAGING FACILITY
Working to client specification and architectural plans, TCi proceeded to undertake structural engineering and material procurement, engaging collaboratively with suppliers and service providers to ensure the best possible quality and value at every stage. With costs and designs agreed, site operations commenced.
Live Environment Management and Containment Solutions
The entire project was delivered within a live factory environment, protected by a metal-framed containment system constructed in GMP conditions, comprising a white, flame-retardant heavy-duty outer sheet, sealed from floor to underside of roof liner. Site access was via dedicated, zipped and sealed containment areas under negative pressure.
Designated access and a separate site office was established to minimise impact of works and prevent contamination paths. An on-site cleaner was provisioned as standard to ensure work areas and access paths were kept free from contaminants and debris.
The delivery
A loadbearing steel substructure was assembled to accommodate ducting, services, partitions and the suspended ceilings. A large mezzanine floor was assembled in adjoining warehouse space to accommodate the dedicated HVAC and dust control systems.
Following a value engineering process, TCi was able to save the client approximately £23k in steel costs after reassessment.
An Altro quartz resin flooring technique developed by TCi with the client underwent further continuous improvement to include a stainless-steel bead, creating a visually smoother and easier to clean/maintain finish over the large floor area.
Due to the central location of the facility, access for materials and machinery had to be carefully planned to include accommodation for the manufacturing equipment installation. A corridor surrounding the three controlled production areas also featured built-in pressurised air supplies to power air skates during the installation and removal of equipment.
PROJECT FEATURES
- Steel supporting structure throughout
- Ultra-hygienic Altro Quartz resin composite floor
- Puracore 50mm honeycomb partitioning
- Fixed, sealed glazed window system
- Fire-rated roller-shutter door
- Clean room rapid action door system
- Mezzanine floor
- Fire alarm & sprinkler system
- Dust control LED lighting to provide >500lux @ working height
- Amstrong Burgess clip-in tile suspended ceiling
- Fully isolated HVAC system with cross-contamination prevention and HEPA filtration
- GRP Swing Doors
TCi is listed and verified as an approved installer for Puracore® clean room partitioning and ceiling systems, SIKA GRP impregnated resin wall & floor finish and Altro resin floor finishes.
COMMISSIONING & QUALIFICATION
A comprehensive commissioning and qualification process was undertaken to ensure the facility achieved the technical performance required for MHRA and FDA compliance.
Full IQ/OQ documentation was completed in accordance with the client URS/DQ and traceability matrix prior to handover. Additionally, O&M manuals were created, providing the client with everything required for immediate occupation and operation of the workspace.
An MHRA inspection was carried out during the works and TCi was commended for segregation of works environments/clean zones.
project outcomes
The programme was completed on time and on budget, to exacting requirements.
The resulting facility reflects a demand for ultra-modern, easy to maintain workspace and efficient, large-scale production. By working closely with the client, TCi has been able to manage the relocation of offices and production lines in order to cause minimum impact to the daily operation of the plant and a fully compliant, high-quality outcome for all stakeholders.
CONTACT THE TEAM TODAY
TCi Construction Works provides construction, refurbishment, fit-out and infrastructure services throughout the UK. Combining technical expertise with a collaborative approach, we deliver high-quality projects that meet our clients’ objectives from concept through to completion.
Our specialist team works with you to design and install a high-quality, professional environment, ready for occupation.
