Our team provided construction management services over a 10-year period to reconstruct existing facilities on the Fresenius Kabi campuses in Melrose Park. Extensive infrastructure upgrades and structural improvements modernized the labs that produce biopharmaceuticals including the world's first protein-based nanoparticle chemotherapeutic compound.
Two existing cleanrooms were rebuilt during a 3-week shutdown of 24/7 construction. The rooms were demolished and rebuilt with new HVAC systems that extended down from the roof into the new cleanroom. Walls and ceilings were installed with stainless steel HEPA housings for critical air ﬂow in front of lyopholizers in loading rooms to meet strict FDA and EU requirements.
The microbiology lab was reconstructed in phases while a portion was still in use as well as two temperature-controlled rooms and an ISO Class 7 (10,000) cleanroom was upgraded during seven-day 24/7 shutdown over the holidays.
The Cornell facility was completely remodeled from top to bottom — upgrading the fire pump, motor control center, all air handlers, exhaust fans, boiler and electrical service. Even the storm drain piping was rerouted and the roof replaced.
At Ruby Street facility, we installed a new steel support structure above the existing barrel roof to support a new 500-ton chiller and 6 new rooftop units. We also replaced existing cleanroom blower motors in ductwork, and installed new fire protection as each phase was completed, replaced microbiology lab, installed new switchgear, and connected a temporary generator.