Cyma Builders was selected as the construction manager for a programmatic effort to relocate an existing R&D facility located in Radnor, PA to Malvern, PA and Spring House, PA. The Malvern renovations consisted of a complete renovation to 35,000 SF of an existing Warehouse and Office Building to construct new Analytical Labs, Formulations Labs, API Bioreactor Suites, Wash Room Facility, API Freezer Farm, Hazardous Storage Space, Mechanical Room, and Office Space, as well as the addition of 16,500 SF of new asphalt parking lot space. Existing cryofreezer farms in the existing building footprint were maintained and operation throughout the duration of the project. A separate facility was renovated on the Malvern Campus to relocate the disrupted warehouse functions. The overall project was put under an aggressive schedule in order to allow for vacancy of the Radnor facility without any lease extensions.
In order to mitigate some of the schedule constraint, Cyma worked with the Design Team (Johnsrud Architects & Genesis Engineers) to develop and issue long lead pre-purchase specifications and critical early construction packages. Construction commenced with the demolition of the existing footprint and the installation of new double wall underground process waste systems, column footings and an underground process waste water recycling system/lift station. Structural steel platforms required for new rooftop air handling units, exhaust fans, and energy recovery systems posted up from the building slab were also installed with early design packages in order to maximize schedule efficiency.
For the required HVAC system upgrades, Cyma Builders pre-purchased and installed two laboratory rooftop chilled water cooled, hot water heated air handling units with an energy recovery coil, a gas fired packaged DX rooftop office air handler, 30,000CFM laboratory exhaust fan, two 180 ton air cooled chiller and pump systems, two 1800MBH gas fired heating hot water boiler and pump systems and a new 70BHP gas fired steam boiler and de-aerator skid. Laboratory HVAC systems were fit-out with high acting Venturi air valves for supply, exhaust, and return airflow, fan powered terminal HEPA filters, chilled beam technology for coiling, and hot water reheat for heating. Office spaces operated on a VAV system utilizing hot water reheat coils.
Major infrastructure upgrades for the process and plumbing systems of the project consisted of the pre-purchase and installation of a new duplex 200ACFM vacuum pump skid and liquid separator, packaged DI water mixing bed skid, softened water skid, vial washer, and glass washer assembly. New incoming domestic water, sanitary, and gas services were brought into the building from the existing utility company feeds outside of the building footprint. Compressed air, carbon dioxide, oxygen, helium, and argon gases were distributed throughout the labs via cylinders and automatic change over manifolds. A new liquid nitrogen system was installed along with a vaporizer to serve as the building’s gaseous nitrogen system.
While the site currently had adequate capacity from the existing PECO service and existing generator set, the existing distribution infrastructure was undersized and needed to be replaced. Cyma installed a new 3000A main switchboard, 800A motor control center, 400A ATS, 200A ATS, 225KVA UPS, 600A motor control center, and four 800A distribution panels. A temporary generator was utilized during all major shutdowns in order to keep the existing cryofreezer farms and their associated MEP infrastructure operational at all times.
The Spring House renovations included 10,000 SF of laboratory renovation to accommodate the relocated program. Additionally, all proposed renovation areas were occupied, requiring enabling moves to other spaces throughout B42. All work was heavily coordinated with end user groups to minimize down time and facilitate the moves. Existing building utility systems were leverage for all plumbing and HVAC upgrades; however, all utility shutdowns were closely coordinated to minimize impact to daily business function. To support emergency power requirements, a new 750 kW emergency generator was install exterior to the building with fuel oil connection hard piped to the onsite storage building. New feeders were brought in to support the new emergency loads, as well as back feed existing building emergency services.
All critical work in both Malvern and Spring House was completed at the conclusion of 2013.