Pharmaceutical

Australian Red Cross Blood Service, Perth Processing Centre Refurb. Stg1-4

WA - Australia

Refurbishment and modernisation of the 55 year old Processing Centre. This major redevelopment will occur over five stages. The project will contain substantial construction and fit-out work including a high proportion of laboratory and production facility areas, storage and cold/freezer rooms, electrical and mechanical services upgrade, IT cabling, civil works specific to the operation of the Blood Service and thus governed by the Principles of Good Manufacturing & Good Engineering Practice.

Johnson & Johnson Renaissance Project

Shanghai, China

Project Renaissance is a Brownfield project with site area of 9,778 m2, which will provide additional manufacturing capacity for J&J’s liquid pharmaceutical products to meet increased market demand. The manufacturing facility will include raw materials handling, washing, liquid pre-mix and mixing processes and filling / packaging lines. The new site will also include utilities, general office areas, staging area and an existing canteen to support the manufacturing operations. Manufacturing capacity from both the SJJP facility and the J&J Xian (XJP) facility will be moved into the new liquids manufacturing plant.

Eisai New Injection Project

Suzhou, China

This Brownfield project of approximately 50,000m2 is for a new pharmaceutical injection plant. The project comprises three buildings including the two-level plus basement and mezzanine injection production building, annex building housing steam plant and pump station and a class A hazardous goods storage building. Level 1 of the production building houses a production workshop and storage, level 2 is dedicated to laboratories, utility room and offices.

CSL Limited Cell Culture Facility

Vic Australia

A greenfield project at CSL’s existing Broadmeadows facility.  This four storey facility includes a split level ground floor with offices, amenities and documents storage area, trade waste treatment area, decontamination rooms, -40 degrees freezer and mechanical plant area including the housing of Chillers, High voltage switch-room, Main switch rooms and purified water systems.  Level 2 is the main production area of the building with PC2 level clean-rooms.

Winner – Master Builders Excellence in Construction Awards 2013 Industrial Buildings

AstraZeneca Broad Market Manufacturing Site Project

Taizhou China

AstraZeneca, one of the world’s leading Pharma companies, is establishing a new pharmaceutical manufacturing facility in Jiangsu Province, China. Known as China Broad Market Manufacturing Site, in the China Medical City, Taizhou, the 51,000m2 project comprises Sterile dry powder filling for injectable Cephalosporin products, and Oral Solid Dosage products. Phase 1 of the $230M project was recently completed and Phases 2 and 3 are progressing well.

Boehringer Ingelheim Panda Project

Shanghai - China

This 17,000m2 project includes an Ampule and Solids packaging building (APP), which houses QA/QC offices, general offices and multiple packaging lines.  The APP Building is linked to a fully automated lights out High-Bay Warehouse (HBW).  At 22m high this warehouse is equipped with a European racking system and demands strict tolerances in base building construction.  The 3-level Centre of Competence (CoC) houses high quality lab and working offices.

Associated works include Hazardous Goods store, Pumphouse and Firefighting Water Tank, Waste, Gate Houses and upgrades to the existing infrastructure including a new 4000KVa substation, underground services, ring road and packing areas.

Elizabeth Macarthur Agricultural Biosecurity Upgrade Works

NSW - Australia

The $56 million ($43.0M construction) upgrade of biosecurity facilities included the construction of a large new secure laboratory precinct. It will include high-containment certified PC2 and PC3 laboratories for virology, bacteriology, microbiology and molecular biology; refurbishment of existing animal and plant health laboratories, and an upgrade of electrical and safety systems.
Cockram Construction was engaged in an early tender involvement (ETI) process with NSW Public Works which essentially required us to provide feedback on documentation and potential design issues/risks. At this time we identified one of the key issues for the client was the programme and at tender time proposed a temporary PC2 certified laboratory structure to house researchers between moves so as not to disrupt their research. This in turn also cut 12 months off the practical completion date.

Melbourne Centre for Nanofabrication

Australia

As the main facility of the Victorian Node of the Australian National Fabrication facility, this project links seven university-based nodes to provide researchers and industry access to state of the art fabrication facilities. Based at Monash University Science Research Park, the 3,800m2 building 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. Cockram was subsequently 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.

Winner – Master Builders Excellence in Construction Awards 2011 Industrial Buildings

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Baxter Healthcare Expansion Project

Guangzhou – China

The Baxter Healthcare facility produces sterile renal products in soft plastic bags.  Cockram’s project scope included a full development of two new filling lines and the construction of a multi-level manufacturing building approximately 20,000m2 with associated facility and utility systems and a new 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

Hangzhou – China

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

The 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 continue 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.

Novo Nordisk Filling Plant Project

Located on a Greenfield site of approximately 98,000 sqm, the project was constructed in two phases.  The completed facility has enabled Novo Nordisk to meet the rapidly expanding demand for insulin products in China. This filling site comprises formulation, filling, inspection and packaging of Penfills, and some packaging of FlexPen (pre-filled insulin pens), in addition to vial packaging.

Pfizer Utilities Infrastructure Project

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.

Pfizer PSB 2

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

Mumbai – India

With a floor area of 5,000m2 over four 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 nine reactors, of which six are glass lined and three 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

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

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 provided 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.

Roche Head Office and Conference Centre

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.

Eli Lilly Refurbishment

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.

Victorian Infectious Diseases Research Laboratory

VIC – Australia

A 3,000m2, 4-level fitout including basement car park and plant areas, entry foyer and laboratory areas, administration, lift and replacement of the roof.
Laboratory benches were constructed using the “flexlab” system and existing bio hazard cabinets and fume cupboards were relocated from the existing premises at Fairfield. The Level 4 area included two PC3 and one PC4 laboratory. All waste from the PC4 laboratory was designed for treatment by a special trade waste system located in the Level 1 area which included processing with chemicals and 130° temperature steam prior to entering the sewerage system.
The project received special interest from N.A.D.A. and C.S.I.R.O. due to the uniqueness of the PC3 and PC4 laboratories and trade waste systems.