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 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.
Cyma was awarded a construction management contract to perform complete interior demolition and new fit-out of approximately 8,500 SF of new laboratory in Lexicon Pharmaceutical’s new facility.
New work began with construction of a self-contained penthouse mechanical unit built to supplement (27) fume hoods. New piped gas utilities, a new DI water system, and new architectural finish package including lab grade millwork, working surfaces and fixtures were also required of this project.
The construction was completed successfully on a fast-track schedule and within the project budget.
Cyma completed a project for Monell Chemical Senses in downtown Philadelphia at 35th and Market Streets. The project required conversion of an existing 12,500 SF office plan to a new chemistry lab on the third floor of a four story building, with occupancy on the first, second, and fourth floors. Working in downtown Philadelphia, combined with working inside an occupied building made this a challenging project to say the least, however Cyma has vast experience dealing with both difficult scenarios.
Existing toilet room cores adjacent to the work area were upgraded and new MEP work included a new supply/exhaust/return air ductwork system with a hot water reheat, new power panels fed from exiting distribution panels, distribution of lab grade power and lighting, a new wet sprinkler system from an existing stand pipe, distribution of lab gas systems from existing building systems, lab waste and vent distribution, domestic water distribution for lab use. All new lab finishes were implemented, including painted metal casework with epoxy counters.
Cyma Builders renovated an existing R&D Facility for the Bioprocess Sciences and Purification Sciences division, which supports Centocor’s manufacturing operations including trouble-shooting, technology transfer, and development of improvements to current manufacturing methods. Much of the work took place directly adjacent to occupied space which required heavy coordination with tenants and building management in order to properly coordinate utility shut-down schedules and logistics. New installation included distribution of steam, condensate, and chilled water for HVAC, process utility, and process use. Installation of lab gas manifolds from bulk storage and distribution for process use, installation of new below slab process waste collection system and new 480V electrical service, secondary gear, and distribution was also incorporated into this project. We also replaced the 208V electrical service, secondary gear, and distribution and built new IT distribution closets. New construction of cold storage units, a new Analytical Lab, administrative offices and new toilet rooms completed this phase of the project.
The second phase of the Building 1 Masterplan Project involved the coordination and installation of new MEP infrastructure to support laboratory systems. We were again working directly adjacent to occupied areas and successfully coordinated shutdowns and access with building management and tenants. The second phase also required constructed of a centralized wash & autoclave facility, distribution of utilities for a new chilled water air handling unit and installation of a new air-cooled chiller that feeds the new chilled water air handling unit.
