BC3.2 Bio Cork Project
Cork, Ireland
BEST PROJECT
Sent by: Johnson & Johnson
Owner: Innovative Medicines, Johnson & Johnson
Leading design company | Contractor: Group PM
Electrical and instrumentation: STS group
CSA subcontractor: Sisk
This large and complex expansion of a biologics manufacturing plant increased capacity by 75% by adding three production bioreactors, each of 15,400 liters, as well as associated seed reactors and expanded storage cold rooms, freezers and central services.
The team was challenged to run the project in a live manufacturing environment, which increased the risks and complexity of the work. Crews installed and removed more than 1,000 large scaffolds in active work zones, most of which were confined spaces. The team developed a tagging system that used cable ties on live services to ensure operations did not accidentally close any valve levers. They also had the shops use sound-proof booths to eliminate risks.
Flexibility was key to mitigating the challenges of the aggressive schedule. Early planning helped the team identify risks and mitigate them. Business partners worked double shifts and weekends to address worker density issues.
The team used 4D building information modeling to visualize progress at all stages of the project, without using any paper at any stage. The digital approach carried over to invoicing, and team members say it helped make construction a smooth and efficient process with a significant reduction in punch list items.
With its completion, the facility is enabling the owner to seek new solutions to advance the manufacturing of immunology and oncology drugs.
