Cyma Builders completes OSD Manufacturing Facility in California

Cyma Builders was selected as the construction manager for a Weigh/Dispense/Blend Suite to facilitate relocation of manufacturing operations to a California facility location.

Working with CRB as the design lead, the client considered the numerous approaches and technology to achieve the throughput required for the space. Cyma Builders assisted in cost analysis of the options and coordinated the bid process for all process equipment , specifically Downflow Booth and Blender equipment, and assisted with management of the submittal process.

The footprint of the new Weigh/Dispense/Blend Suite was carved out of an existing TSA Warehouse, requiring heavy coordination with daily operations. Concrete pits were sunk into the existing slab at three (3) locations to allow flush mounted scales to be installed for tote weighing. A new steel frame was erected to support an AHU platform and process equipment structural requirements, while the remainder of the Suite was built with structural/seismic considerations using cold formed metal framing. The walls/lid of the Suite were rated to provide a walkable surface for maintenance of MEP systems serving the space. A new Buffalo air handling unit was installed, along with air valves and terminal HEPA filters to comprise the HVAC system. Plumbing utilities were extended off existing site distribution and infrastructure, including Purified Water, Compressed Air and Potable Water. A new 200 A bus duct plug was installed to support the new HVAC, process and general distribution electrical loads for the space. All shutdowns of plumbing and electrical systems were carefully coordinated with the active site to avoid any impact to active manufacturing operation and production schedules.

In addition to the Weigh/Dispense/Blend upgrades, modifications were required to a second floor tablet press dump stations to accommodate installation of new compression equipment. The existing second floor space was a combination of charging suites, ovens and staging areas, making the unification difficult from and architectural and HVAC standpoint. Also, temporary protections had to be devised to isolate an existing dump station that had to remain active for portions of construction due to ongoing qualification runs. Following demolition of all existing equipment and architectural components, a new HVAC system was installed served by a roof mounted Buffalo air handling unit. Electrical and plumbing utilities were extended off existing site distribution/infrastructure. Heavy coordination was required with the two (2) new tablet presses being installed on the first floor. The second floor slab was cored at strategic locations for installation of new stainless steel dump chutes and process control panels. Finishes were then patched at the suite below to restore them to original condition.

Both spaces were finished with DensArmor walls/ceilings, epoxy paint, Stonhard epoxy floors and stainless steel bumper/corner guards. Chase SS sliding doors were installed at most new airlocks and suite, while ASI high speed roll-ups were installed for access to the Downflow Booth and Warehouse airlock. Specialty systems installed for the space included door interlock/security controls, PA system and fire alarm system.

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