In September, Cyma Builders participated in several career fairs, including events at Penn State, Thomas Jefferson University, and Pennsylvania College of Technology. Cyma conducted interviews for both internship and full-time positions, reinforcing its commitment to cultivating the next generation of talent and strengthening the company’s future.
On Wednesday, June 26, 2024, Cyma Builders and its trade partners hosted a steel topping-out ceremony to celebrate a significant milestone in the Almac NAHQ Expansion Project. This timeless tradition places the final major piece of structural steel, symbolizing a key achievement in the construction process.
Contractors and client personnel gathered to witness the milestone and joined a celebratory lunch after installing the steel.
Cyma Builders is excited to continue progressing toward the next phases of this project!
Cyma recently held a site safety lunch and learn event for its project with DSM, recognizing contractors for their proactive “good catch” submissions and safety observation reports. These sessions addressed a range of site-specific safety topics and included a mandatory “Focus Topic,” offering contractors an opportunity to meet OSHA compliance requirements while reinforcing critical safety concepts and practices.
For July, the Focus Topic centered on Bloodborne Pathogens Awareness and Exposure Control Planning, ensuring everyone on-site stays informed and prepared.
For this project, we transformed a warehouse into a state-of-the-art dynamic laboratory space, complete with new lab areas, mechanical mezzanines, and upgraded utilities.
The project encompassed diverse construction and renovation tasks to meet the client’s requirements. Central to the transformation was the creation of new lab spaces, including supporting facilities like restrooms and a loading dock area. Key features of the fitout included a 10,000 square foot mezzanine that required robust footings and steel dunnage. The new mezzanine was constructed to accommodate essential mechanical equipment such as rooftop exhaust fans and air handler units. Extensive ductwork ensured efficient airflow and ventilation throughout the facility.
Upgrades to the electrical service were crucial, necessitating collaboration with utility companies and ownership for installation of new distribution gear and dedicated panels for lab equipment. Additionally, new drainage and utility systems, including gas services, were integrated to support lab operations.
Despite challenges like excavating and installing mezzanine footings and coordinating utility upgrades with local authorities, the project excelled. Through meticulous planning and innovative solutions, disruptions were minimized, ensuring seamless operations. We are very pleased that the project not only met but exceeded the expectations of the client, providing a versatile and state-of-the-art research environment for years to come.
Cyma Builders proudly announces the successful completion of Phase 2 at August Bioservices, marking a milestone in our commitment to construction excellence and client satisfaction.
Expanding GMP Production Spaces and cGMP Warehouse Capacity
The primary objective of Phase 2 was to augment the existing GMP production spaces and cGMP warehouse capacity at the facility. This involved constructing and finalizing the cGMP warehouse, completing CNC and Process corridors, and installing necessary MEP infrastructure.
The culmination of Phase 2 resulted in several key accomplishments:
6,500 SF of new cGMP warehouse capacity
Two new 175 BHP boilers
Two new 128 ton chillers
A new clean compressed air system
A new WFI and CS Generation and Distribution system.
Six new roof top air handlers to support the new spaces.
These enhancements provide the foundation for improved operational efficiency and capacity expansion, empowering August Bioservices to meet growing demands and advance their mission.
Overcoming Challenges with Precision and Expertise
Despite challenges, such as the presence of extensive limestone bedrock and the proximity to the Colonial Natural Gas Pipeline, we successfully executed blasting activities. This was achieved through meticulous planning and collaboration with subcontractors and pipeline owners, ensuring zero incidents.
Following blasting operations, we swiftly transitioned to constructing the building shell using a steel superstructure with precast panels for durability. Simultaneously, interior fit-out work commenced on the warehouse, and despite supply chain delays, our proactive approach and strategic partnerships mitigated potential setbacks.
Looking Ahead: Phase 3 and Beyond
As we celebrate Phase 2’s success, we look forward to Phase 3’s growth. Scheduled to start in late Q1, it will introduce two formulation suites for custom filling lines. Our team remains dedicated to delivering excellence at every stage of the project, driving innovation and progress in the field of construction.
The successful completion of Phase 2 at August Bioservices underscores our commitment to quality, safety, and client satisfaction. We extend gratitude to stakeholders for their collaboration, shaping the future of construction excellence. Stay tuned for updates as we proceed to the next phase!
For inquiries or to learn more about our services, please visit our website or contact us directly.
Cyma Builders, Almac, & the design partners gathered to celebrate the groundbreaking of the Almac North American Headquarters Expansion Project (Souderton, PA). This transformative initiative will enhance the existing campus by adding an impressive 113,410 square feet, increasing parking capacity, and implementing substantial site and utility infrastructure improvements.
Cyma Builders completely renovated an existing pharmaceutical production space for August Bioservices, helping to facilitate their future business goals. The client purchased the facility with the intent of developing an extensive CDMO capability located in the middle of the United States.
The initial step was to revamp the existing facility to enable manufacturing operations while the future buildings were being designed. This involved overhauling the mechanical and electrical systems, and installing new clean process utilities to support the filling process that was intended for the site.
Significant work was also done on the existing equipment mezzanine above the suites, which included removing of AHUs and installing of new ductwork. This was coordinated with other utilities and equipment to ensure clear maintenance access.
Additionally, Cyma assisted the client in arranging for a new electrical service from the public utility company, capable of supporting the increased power needs from the current renovation and future expansion projects.
This project was executed during the COVID-19 pandemic. As a result, the project suffered significant challenges related to supply chain issues which affected stainless steel piping, electrical breakers, and mechanical infrastructure.
Cyma Builders successfully completed the GMP production suites for one of our confidential clients! The purpose of this project was to expand upon the facility’s existing GMP production spaces with four new Grade B Gene Therapy suites as well as an additional freezer room.
We are proud to share that our team was not only able to accomplish the expansion successfully, but also overcome the project’s unique challenges in a seamless way.
Creating an Efficient, Workable and Easily Accesible Layout
One of Cyma’s initial tasks was to create an efficient and workable layout while also ensuring that all areas would be easily accessible from the GMP clean room’s walkable ceiling. There was an extensive effort to coordinate all trades in the ceiling and to ensure that all the ductwork, process piping, and mechanical system would be accessible from this ceiling. This was achieved utilizing BIM modeling and coordination sessions for a 10 week period at the onset of the project.
Overall, the client was very happy with the result as it is relatively easy to access anything from the walkable ceiling installed during this portion of the project!
Preventing Covid-Related Equipment Delays and Supply-Chain Disruptions
One of the main challenges of the project was dealing with supply chain disruptions and COVID related delays to the equipment. Cyma created a tracking matrix early in the job and coordinated with subs on all components to try and identify components that suffered delays as quickly as possible. Once they were identified, Cyma worked with the manufacturer to try and mitigate the delay and prevent the component from delaying the overall project.
In the end, Cyma was able to prevent any equipment related delays from affecting the overall delivery and integration of the production suites into the existing facility!
Expanding and Integrating New Infrastructure with Minimal Disruption
Another challenge on the project was actually segregating the project from the existing facility and ensuring there was no impact to existing GMP operations. This was achieved by creating a comprehensive utility shutdown matrix which allowed the facility to see when and how every project related shutdown was being performed on the project, and whether or not it would be disruptive to the facility.
The facility was then able to coordinate with their end users and Cyma to select a date that would have the least impact. During these critical shutdowns, Cyma would draft and circulate a method of procedures to further coordinate with the facilities maintenance team so they would know what tasks were being performed throughout the day of the shutdown.
This process was very helpful to both Cyma and the facility as it allowed the shutdowns to be well planned and adapt to unforeseen circumstances as needed.
Phase 2 Expansion has commenced and is off to an explosive start, both literally and figuratively! Breaking ground on this expansion took on a whole new meaning when the project team utilized explosives to blast through the existing bedrock.
All this effort will eventually lead to the foundation that will house a new aseptic manufacturing facility with the capacity to double their fill/finish capabilities.
Cyma Builders is proud to announce it successfully completely the first of two (2) manufacturing expansion projects of August Bioservices Nashville manufacturing operations. The first expansion focused on renovating August Bio’s existing facility to increase manufacturing capacity and development capabilities for liquid and lyophilized vial filling, prefilled syringe fillin, IV bags and terminal sterilization.
Together, August Bioservices & Cyma Builders are growing pharmaceutical manufacturing in Nashville, Tennessee!
Watch the video showcasing August Bioservices manufacturing expansion here!