Bio-Pharmaceutical

CSL Limited 5000L Cell culture Facility

AstraZeneca Broad Market Manufacturing Site Project

December 2013 ($230.0M)
Taizhou China

AstraZeneca, one of the world’s leading Pharma companies, is planning to establish a new pharmaceutical manufacturing facility in Jiangsu Province, China. The proposed manufacturing facility is named China Broad Market Manufacturing Site, which is located in China Medical City, Taizhou, also known as “The Medical City” due to the rapid development of medical research centers. The land size of approximately 92,000m2 and gross build up area of approximately 51,000m2 including two main production areas:
• Sterile dry powder filling for injectable Cephalosporin products
• Oral Solid Dosage products
The project consists of two phases, Phase 1 and Phase 2. Both phases are considered as one project and will be built now with different fit-out contents.
As the leading CM Company for Major Pharma projects in China, Cockram Projects is contracted to provide Procurement and Construction Management Services. The services will involve a team of approx 40 CM professionals for a 2 year period. Cockram’s past experience over the past 20 years in China on similar projects was instrumental in AZ’s decision to select Cockram over other international Engineering firms.

Boehringer Ingelheim Panda Project

December 2013 ($50.0M)
Shanghai China

The project is the enlargement of the production and packaging capacity of Boehringer Ingelheim’s (BI) existing Shanghai site, to fulfill the requirements of the Chinese market and other regional markets. The total constructed new building area is approximately 17,000m2 for this current phase due for completion in 2013. Cockram’s role is the Procurement and Construction Management Company responsible for the execution and delivery.

The scope of the project includes Four new major buildings & two smaller buildings including an Ampoule & Solids packaging building (APP), a High-Bay Warehouse (HBW), a Centre of Competence (CoC), a New Canteen (CAN), a New hazardous goods store building (HGS), and a New south gate house (SGH). Also included are modifications for a new shipping & receiving area, a new QA/QC Lab, alterations to site infrastructure (e.g. new 4000KVa substation) and Alterations to roads & parking.

Due to the project being constructed on a fully operational pharmaceutical manufacturing site, extensive planning and great care has been required to ensure facility operations will not be impacted. Heavy construction will occur beside the existing facility and the team will not only deal with many constructability issues, but also need to make adequate consideration of the many GMP and regulatory issues to ensure the daily site operations are not impacted.

Australian Red Cross Blood Service

December 2011 ($60.0M)
VIC – Australia

Fitout of an existing building for the purpose of blood processing, production, sampling and administration for the Australian Red Cross Blood Service. The facility is the Victorian and Tasmanian Principal Site (VTPS) of the ARCBS. The scope included all fitout and services, including the provision of all new plant and equipment to approximately 16,500m2 with a Basement, Ground Floor, First Floor and Second Floor.  Consisting of Offices, staff breakout and meeting rooms, Reception, Laboratories, warehousing, Cool & Freezer rooms, Plant areas and landscaping.

Awards:
Construction of Commercial Buildings $30M-$80M
MBAV Master Builder of the Year 2012

Click here for more information.

Pipe Rack Renovation-Lead Based Pain Removal

May 2011 ($3.0M)
Barceloneta – Puerto Rico

Cockram was engaged by Pfizer Manufacturing Facility in Barceloneta to conduct a structural evaluation of the existing pipe rack built in 1972. The purpose of the evaluation was to review the original design drawings and conduct visual inspections to assess the physical condition of the structural members and structural integrity of the pipe rack. Cockram assessed the existing loads on the pipe rack in order to verify if it meets the original design limits and reviewed if pipe rack has capacity to support additional pipes. We concluded that the pipe rack shows severe corrosion and needs to be repaired to maintain the integrity of pipe rack. Cockram proposed a five step remediation program for each pipe rack section.

Baxter Healthcare Expansion Project

March 2011 (US$40.0M)
Guangzhou – China

The facility will produce sterile renal products in soft plastic bags and the project scope includes a full development of 2 new filling lines and the construction of a multi storey manufacturing building around 20,000 sqm with associated facility and utility systems and a new additional 2nd floor office adjacent. The facility will have full sprinkler protection and will be required to meet both local Fire Code and Factory Mutual standards requirement.

Sanofi Minsheng Relocation Project

December 2011 (US$30.0M)
Hangzhou – China

This Relocation Project is a joint venture between Hangzhou Minsheng Pharmaceutical Co., Ltd. and Sanofi-Aventis.

The current facility specializes in manufacturing OTC items such as vitamins and health products, predominantly coated and non-coated tablets, capsules and soft gelatin capsules, including packing of the products in bottles or blister packaging. The existing plant will be under ongoing production during the relocation phase.  Major equipment will be relocated and started up in the new facility so as not to affect the supply to market.

Melbourne Centre for Nanofabrication

December 2010 ($22.0M)
Vic Australia

The Melbourne Centre for Nanofabrication (MCN) is the main facility of the Victorian Node of the Australian National Fabrication facility. The project links seven university based nodes to provide researchers and industry access to state of the art fabrication facilities. MCN is based at Monash University Science Research Park in Clayton. The building covers 3,800m2 and is made up of three main functional pavilions. The research pavilion is one level plus a dedicated mezzanine plant room with trafficable ceiling. The pavilion contains Class 10,000 clean rooms, Class 100 clean rooms, PC2 laboratory, general labs and associated offices and amenities. Following completion of the initial project, Cockram was awarded the Class 100 clean room fitout and we worked closely with the client to ensure minimal disruption to the operation of the newly completed facility.
The Class 100 area is of the highest standard of clean room construction.

Awards – 2011 MBAV AWARD WINNER
EXCELLENCE IN CONSTRUCTION OF INDUSTRIAL BUILDINGS

Novo Nordisk Filling Plant Project

September 2010 (US$300.0M)

Located on a Greenfield site of approximately 98,000 sqm, the project is split into 2 phases, The completed facility will allow Novo Nordisk to meet the rapidly expanding demand for insulin products in China. This filling site will comprise formulation, filling, inspection and packaging of Penfills, and some packaging of FlexPen (pre-filled insulin pens), in addition to vial packaging.

CSL Buiding 4 HVB – R&D Refurbishment

August 2009 ($6.9M)
VIC – Australia

Internal demolition of an existing 6 level building whilst maintaining operation on two floors. The RC building with three occupied floors of laboratories and three interstitial plant floors was required to be gutted, and redressed to allow the new installation. CSL’s R&D use for the laboratories required a mix of PC2 small and large scale rooms, and general lab space. The large scale PC2 rooms, to incorporate relocated and new fermentation plant, were required to meet stringent air leakage requirements in the construction procedures and materials selection to ensure certification by OGTR and AQIS and to enable the fumigation of the rooms to be effective.

Pfizer Utilities Infrastructure Project

July 2009 (US$11.0M)
Mumbai – India

Infrastructure upgrade throughout Pfizer’s 23 Acre Mumbai facility. Included was Roads, drains, paths, lighting and landscaping, a gatehouse security building, meter room to house the incomers for the 22kV site power from the local authorities and a cable, 350m from the meter room to the Panel room which houses all the site wide electrical distribution panels and transformer, a pipe rack runs throughout the site providing services to all buildings.  Adjacent the panel room are 2 1200kVA diesel generators for 100% power backup, a fuel oil tank farm provides fuel oil for the generators, diesel fire pump and boilers.
A 750m3 water tank and a pump-house supply water to the site and fire sprinkler and fire hydrant systems to all of the buildings throughout the site. A utilities building houses the Soft water filtration system and associated plant and equipment, services are provided from this building to all the others.  This project was not required originally as all services were provided from the adjacent facility however part way through construction all services to the site were terminated which made this project a necessity.

Dow Chemicals R & D Centre

May 2009 (US$130.0M)
Shanghai – China

Three buildings comprising Dow’s 88,000m2 R&D Centre. The larger buildings are the R&D building and the Administration building and the smallest is the Central Utilities Building (CUB).   The R&D and Administration buildings include undercover car park, 64 light laboratories and 1 heavy laboratory, offices, a 700 seat restaurant, Gymnasium, Presidents suite and Badminton court.
The building has an open area through the center with a glass atrium roofprotecting the space.
The CUB building houses the High Voltage and Low Voltage Electrical rooms, Boiler room, Ice chiller tank, Chillers and Fire protection room and holding tank etc.

Pfizer PSB 2

April 2009 (US$13.0M)
Mumbai – India

A 2 level Pharmaceutical Sciences building of approximately 7,000m2.  The facility includes laboratories for process chemistry and safety, Hydrogenation, Scale up unit, QC Lab and Analytical, BMS and IT server rooms and stability ovens and technical space including 30 air handling units, 11 Scrubber units for fume extraction, UPS with battery back-up and Vacuum skid.  Two atria provide natural light to laboratories.
The building also houses meeting rooms and Conference room with Audio visual facilities, staff amenities, canteen, document storage and an acoustic treated training room.

Pfizer API Pilot Plant

March 2009 (US$27.0M)
Mumbai – India

With a floor area of 5,000m2 over 4 levels this facility produces API (Active Pharmaceutical Ingredients) for animal health and comprises laboratories and clean rooms with HEPA filtration and warehousing, DCS and BMS Control rooms, technical service areas, filter dryers, UPS reactor halls with 9 reactors of which 6 are glass lined and 3 are Hasteloy, transfer panels and drum transfer stations, office and warehousing.
Externally there is a cooling tower, below ground slurry tanks, Organic and Aqueous tanks, and a Blast proof room with Hydrogenation, nitrogen generation plant, Solvent storage tank farm and drum storage area.

Lilly Plant Demolition

Dec 2007 ($7.8M)
Mayaguez- Puerto Rico

Cockram was engaged by Lilly to represent the client and provide Construction Management services for the Mayaguez Equipment Salvage Facility Recovery. Our team provided the management & implementation of our safety and environmental program and provided project accounting services on behalf of Lilly.

The project consisted in demo all production building that were not going to be in operation any more, also all tanks from the tank farm area were removed, all the equipment from the building also were removed before the building was demo. More that the half of the plant was demo.

Our team prepared and direct weekly Environmental Health and Safety meetings, were responsible to preparing monthly reports, approving EQB manifests, storm water control program, waste disposal management plan, performed the audits to identify noncompliance areas and implement corrective actions. Conduct regulars Safety and Health audits and inspections to the construction site and contractors workshops to report findings.

Lilly API Plant Retro fit

July 2007
Combined phase 1,2,3
value (US $132.0M)
Guayama – Puerto Rico

Cockram provided the full range of services over the 3 phase project program to retrofit an idle existing API facility. The scope
of projects included  in demolition, rooms retrofit, new equipment installation, new pipe rack, utilities upgrades and instrumentation
modifications. Cockram role commenced with client representative leading the Engineering phase of the project. We also provide
Full Agency CM for phase 1 and 2 of the project. The general scope for Phase 1 included demolition, equipment installation, piping, instrumentation modifications, and architectural modifications around the existing charge room & filter dryer room. The Phase 1 scope also included the necessary tie-ins and planning for future Phase II scope to minimize shut downs and interference when Phase I is in production. Phase II scope includes new structural & architectural alterations and installation of 4 new reactors, filter dryer and conveying & charging systems. To support the increase in capacity for Phase II the following changes will be required: We provided quality assurance and cost controls for the phase 3 project.

Lilly del Caribe Dry Products Compression Suites

August 2005 (US$13.8M)
Carolina – Puerto Rico

Cockram was engaged by Lilly to represent the client and provide Construction Management services for the Encapsulation Suites and Material Movement Corridor for a biotech facility. Our team supervised the construction works using a General Contractor, implemented the safety program, provided scheduling and cost control services and also managed the trade contracts on behalf of Lilly. The Cockram team then continued to provide start-up and validation assistance to the plant team carrying out the Commissioning & Qualification activities.

Roche Head Office and Conference Centre

March 2007 ($23.0M)
NSW – Australia

The project for Roche Products included the construction and fitout of a multi level commercial building with gross floor area of 4,800sqm, refurbishment of the existing administration building and cafeteria, car parks and modifications to warehousing buildings, complete with complex building and process services installations.  Key to the project is the integration of environmentally sustainable initiatives with the design and operation of the facility.  The project was delivered in an operating facility. Continuity of the existing operations was paramount thus an integrated operations and construction schedule was developed in cooperation with Roche Products.  The site is also a highly secure facility which required project conformance to various security procedures and protocols. Cockram developed special training and induction programs with Roche Products.

API Reactor Replacement

Dec 2004 ($5.0M)
Arecibo- Puerto Rico

Cockram have been awarded this fast track, multi staged API facility product expansion project.  Due to the need to introduce new products to the existing facility, the scope consisted of new piping/controls and replacement of two reactors.
The project are run in multi shut down phases and staged engineering release, all to match the existing production capacity and tight product introduction time frame.
The Construction Management  at risk execution consisted of acquiring suitable contractors, arranging tender packages, bid analysis, site supervision, safety management, cost control and contract administration, commissioning/start-up, validation support and site supervision.

Pfizer Manufacturing Upgrade, Packaging Hall and Roof

July 2004 ($14.4M)
NSW – Australia

This project for Pfizer Australia was undertaken whilst the entire manufacturing area was refurbished in stages without interrupting any planned manufacturing processes.  The roof replacement project comprised the addition of a new roof structure over the existing manufacturing facility without disrupting the ongoing operations of the facility. All of the existing services under the new roof line were also to be extended.   The manufacturing upgrade involved the complete modernisation of the existing pharmaceutical manufacturing facility.  The scope of works included demolition of all the existing walls, ceilings and services, followed by a completely new internal clean room fitout with all new services.  The packaging hall project involved the extension and upgrade of the existing pharmaceutical Packaging Hall, Utilities Room and Workshop.   The major emphasis for this project was the minimisation of disruption, nil unplanned impact on production schedules and the maintenance of existing services to the production areas.

Scholle Packaging Facility Fitout

November 2003 (US$0.5M)
Suzhou China

Scholle Industries appointed Cockram to undertake the general construction services for its leased facility. The main scope of Cockram’s services included: general construction services, local project construction permits and approvals, quality controls, program controls, construction management and safety controls, project completion and as-built documentation.

Eli Lilly Refurbishment

January 2002 ($8.4M)
NSW – Australia

Cockram provided construction management services for the refurbishment works at the Eli Lilly facility in West Ryde. The site housed offices, laboratory, distribution and minor production facilities.  A new office extension at first floor level was constructed within the existing warehouse and a new conference centre with kitchen facilities, together with a substantial upgrade to the office facilities and services infrastructure.  A new packing room and cool room extension were also completed.  The project included the temporary relocation and reinstatement of equipment and personnel to enable the works to progress and was successfully completed in an operational pharmaceutical grade environment with no unscheduled disruption to production.