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!
Cyma Builders is pleased to announce the restructuring of our operations strategy to best align our resources and employees with a focus toward future growth. As always, we continue to maintain the high level of service our clients have come to expect.
Mike Royce remains Vice President of Cyma Builders, responsible for Cyma’s operations and project delivery resources.
Bill Leonard, PE, will now serve as Director, Project Management. This role will build upon Bill’s current responsibilities of EPCM delivery and design management. In addition, he will manage project managers’ performance and the internship program, focusing on quality control and continuous improvement.
Randy Wieder will serve as Director, Field Operations. Randy will manage all field personnel, specifically Cyma’s superintendents and laborers. This includes resource-loading across Cyma’s projects to ensure all job sites are appropriately staffed. Additionally, Randy will be responsible for field staff performance, quality control, and making ongoing improvements.
Dan Baunach will serve as Director, Process & Technology. Dan keeps his current responsibilities for technical GMP projects and he remains our subject matter expert for delivery of these projects. He will also manage the company’s technology platform for information and project controls needs.
Derek Balent will serve as Director, Pre-Construction. Derek will continue to serve in a leadership role over Cyma’s Estimating and Procurement operations.
Tom Santoli will continue to serve as Director, Safety & Health. Tom heads up Cyma’s Health & Safety Department, develops company policies and procedures, and implements the safety program in the field.
The entire Cyma organization remains committed to successful delivery of our clients’ projects. Please feel free to reach out to any member of our leadership team to address any questions, concerns or future project needs.
Cyma Builders recently completed a portfolio of projects for Charles River across their Malvern & Wayne Facilities. The portfolio consisted of a variety of laboratory, clean room and infrastructure upgrades across the two facilities. Click here to check out more details on the ISO 6 clean room!
Cyma Builders has recently achieved mechanical completion on a 15,000 SF Central Utility Plant Expansion for a confidential client in Jacksonville, FL. Check out the flyover of the new facility below and read more about the project in the profile linked here.
My name is Greyson Messenger. I am 24 years old and a senior Construction Management student at Thomas Jefferson University East Falls in Philadelphia, PA. Since January 2021, I have been interning with Cyma Builders and assisting in project management operations on multiple projects while simultaneously being exposed to the many dimensions of construction management in a real-world setting. Prior to my internship at Cyma, I worked construction as a masonry laborer, landscaper, and commercial green roof installation in Philadelphia and the surrounding area. This field experience coupled with my college courses has given me a well-rounded introductory understanding of what it takes to be a successful and effective project manager.
During my internship, Cyma Project Managers, Superintendents, and Safety have consistently set a great example for workplace professionalism and have imparted a wealth of knowledge in just a few short months that has helped me to better define what I seek to accomplish and achieve in this industry. I am confident this, along with my education, has set me up for success and will be one of the experiences I am most proud of as I enter the professional environment. I will be graduating with a Bachelor’s degree in Construction Management in May 2021 and plan to continue learning as much as possible and working towards being an effective project manager and of benefit to whatever organization I am a part of. Regardless of where I end up post-graduation, I am extremely thankful to have had the opportunity to work at Cyma as I believe it to be an invaluable experience and a great hands-on introduction into the world of construction project management.
GREGORY OBERMEIER, ASSISTANT PROJECT MANAGER
In December 2020, Gregory Obermeier successfully completed an accelerated academic program graduating Magna Cum Laude from Thomas Jefferson University with a Bachelor of Science Degree in Construction Management. He first started working at CYMA Builders and Construction Managers as a part-time employee in 2016 as a Field Assistant. This experience drove Gregory to develop a passion for working in the Pharmaceutical Research & Development sector that further evolved in 2019 when he was advanced to an Assistant Project Manager. During this time, Gregory was able to work on a high-profile R&D Laboratory Renovation Project to support future cell therapy initiatives. Ultimately, he was able to further his knowledge, by working side by side with an experienced project team that allowed him to see a project from beginning to completion through planning, organizing, and managing day-to-day operations.
Prior to working at CYMA Builders and Construction Managers, Gregory worked as a Field Service Technician for a property management firm providing seasonal maintenance to condominiums. From an early age, Gregory always demonstrated a strong work ethic and entrepreneurial mindset from his first working experience at the age of twelve as the founder and owner of Obermeier Lawn Services. This company flourished while he attended La Salle College High School, which prepared him well for the next chapter of his life at Thomas Jefferson University.
At this time Gregory, is working as an Assistant Project Manager who strives to provide a high level of efficiency and dedication to all CYMA Builders’ clients. In the future, he plans to further his education by pursuing a master’s degree in business administration.
CymaBuilders& Construction Managers Creates Successful Safety Culture at Janssen PDMS Expansion Project
Cyma Builders and Construction Managers, in conjunction with our contractors and Janssen Pharmaceutical LLC, successfully created and fostered a proactive, effective and collaborative safety culture on this fast track project.
Janssen Pharmaceutical Research & Development LLC based in Malvern PA selected Cyma Builders to expand their footprint to an existing multi-tenant facility in Charlestown Township. Multiple tenant spaces were combined to create a new, state of the art, 56,000 square foot Lab and Office Facility. Infrastructure upgrades included installing 4 new air handling units (8,000 CFM each) on 4 individual steel dunnage platforms that are free standing along the rear of the facility, duct work distribution to the research labs, refurbishment of over 15 existing roof top units for the office areas, new and upgraded electrical services from PECO and the installation of two emergency generators.
New laboratory services include upgraded glass-wash and sterilization equipment, two cold boxes, new purified water system, compressed air, nitrogen, CO2, vacuum and oxygen distribution systems. Existing lab casework was supplemented with new lab casework and components to suit the end user requirements. New finishes included epoxy flooring, clean room ceiling and epoxy paint.
The project was fully Commissioned and met LEED requirements for Certified status, and the Certificate of Occupancy was issued in mid-May 2018.
From the pre-construction planning stage to project completion, the client and construction team all displayed a genuine commitment to supporting and prioritizing worker safety on the project. The construction team created a hands-on approach to safety that allowed all personnel on the project to become safety advocates, not only being safe themselves but looking out for the safety of others. As the safety culture grew, organizational barriers such as fear and lack of trust in safety, were diminished. Contractors started thinking safety, reviewing their own JSA’s weekly, consulting with the onsite Safety Specialists for ways to conduct tasks safely as they reacted to unforeseen conditions in the field.
The emphasis on worker safety and the establishment of an effective safety culture led to the project far exceeding safety metric goals with over 70,000 hours worked with no Recordable Injuries or Lost Work Time Injuries.
SAFETY CULTURE
‘Safety Culture’ consists of shared beliefs, practices, and attitudes that exist at an establishment or on a project. Culture is the atmosphere created by those beliefs, attitudes, etc., which shape our behavior.
By project completion, the safety effort on the PDMS Expansion Project was an excellent example of an effective Safety Culture.
PROJECT SAFETY EFFORT HIGHLIGHTS
Safety Jeopardy – Created by Mike Royce, Sr. for the PDMS Expansion Project and hoisted at weekly safety luncheons; this safety game consisted of 3 contestants chosen at random from the contractors onsite competing for prizes by answering construction safety questions. Safety Jeopardy questions were selected based on the topic of the toolbox talk presented at the safety luncheon to reinforce the message of the toolbox talk. Contractors took an interest in knowing the topics and, even when not chosen, enjoyed competing and knowing the answers.
Safety Jeopardy and a Safety Luncheon
Weekly JSA Reviews – A project specific Cyma Builders commitment included requiring contractors to conduct weekly JSA reviews and understand, discuss and reinforce Cyma and Janssen safety policies along with any changes or hazards encountered that were not captured in the approved JSAs.
H.B. Frazer conducting a weekly JSA review.
Safety Stand-Downs – Awareness and training sessions intended to help mitigate the impact of hazards in construction. These meetings were held with contractors to discuss safety issues occurring onsite or nationally and also to help inform contractors of recent incidents, near misses, corrective actions, etc. Safety Stand-Downs are intended to interrupt work and focus worker attention on specific safety messages and information.
National Fall Protection Safety Stand Down session held on PDMS project.
Centralized, Organized and Accessible Safety Documentation – Files kept at the site entrance that are readily available for contractors to review & sign daily, weekly or monthly; centralized organization and availability of safety documentation helped workers to review and understand the safety requirements.
For more information about Cyma Builders & Construction Manager, please visit us at www.cymabuilders.com
CymaBuilders& Construction Managers Announces the Safe and Successful Completion of a Critical Steam Shutdown
Cyma Builders and Construction Managers recently managed the successful completion of a critical site wide steam shutdown to replace a main steam distribution header at a large pharmaceutical research and development facility in Montgomery County, PA. This steam shutdown is part of an ongoing $3.6 million-dollar project to replace two existing 500 horsepower BTU boilers inside the Central Utility Plant. The two boilers and the associated steam header provide steam for heating, hot water as well as for critical vivarium and pilot plant operations.
In advance of the steam shutdown, Cyma Builders coordinated all aspects of the outage and worked with the installing Mechanical contractor (Herman Goldner Co., Inc.), site maintenance and engineering, facility personnel and several end users/client groups in order to minimize the impact to site operations.
The steam shutdown started on Friday, September 7, 2018 at 6:00 PM and continued around the clock through Sunday afternoon. The shutdown of the steam supply had to wait for off-peak hours to minimize interruptions to normal daily operations. A temporary boiler was mobilized to the site and piped in to existing steam distribution piping to provide critical steam for the site’s active vivarium. Herman Goldner Co., Inc. and Vasoli Electric Co., Inc. (Electrical contractor) installed utilities for this temporary boiler ahead of the shutdown.
Herman Goldner Co., Inc. removed the existing header and associated piping then installed the new steam header, steam pipes and hangers while working from aerial lifts, scaffold towers and portable ladders. Significant pre-planning and attention to detail was exercised to prevent welding flash and possible property damage in the confined work area; welding screens and fire blankets were installed throughout the work site.
With excellent pre-planning and coordination of contractors and site personnel, this steam shutdown was completed safely, on time and with minimal interruption to site operations.
For more information about Cyma Builders & Construction Managers, please visit www.cymabuilders.com.
