Brief Description

This project involved the retrofit of existing fallow production space and the building of a new extention to house two new secondary pharmaceutical processes for Abbvie. In addition, the existing office and laboratory building at the front of the site was expanded to provide additional capacity.

The project was completed over two phases. Phase 1 involved the MEP fit-out of the existing fallow space which was converted to ISO 7&8 cleanrooms. Phase 2 involved repeating the same work-scope within the new extention. In total, over 7,500m of pipework was fabricated, installed and tested, including over 800m of hygienic tubing to serve clean steam, WFI and CIP services.

In addition to piping services, Kirby also fabricated and installed 5,500sq.m of Class C ductwork and all associated electrical and instrumentation services. We were also responsible for the installation and alignment of all utility and process equipment including centrefuges, blenders, fluid bed dryers, coaters, hoists etc.

BIM Capabilities

Kirby pre-fabricated all piping off-site using isometrics drawn from the 3D BIM model thereby limiting the requirement for on-site personnel in what was a very restricted ‘live’ working environment.

Overcoming Challenges

The over-riding challenge on this project was schedule. The program for Phase 1, which included the installation of 4,500m of overall piping, was 14 weeks to IQ, necessitating 24/7 cycle working and the adoption of shift working patterns. This challenge was heightened due to the congested working environment and proximity to adjacent pharmaceutical operations. Kirby implemented an off-site fabrication approach with JIT based deliveries so as to minimise storage requirements and manpower on site.