Case Study: Primary inoculation and secondary incubation facility
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Contract Scope:
The project included the complete design and construction of an entirely new primary inoculation and secondary incubation facility. It was carried out in two phases, with a total project value of £1.5m.
Acting as principal contractor and designer under the CDM Regulations, the Boulting Group was responsible for heath and safety for the complete project, including supervising and co-ordinating the installation of the client’s equipment.
The project included complete turnkey construction, from foundations to validation and final hand-over. The buildings were erected at an existing site, and construction began whilst the facility was fully operational. Site traffic and personnel had to be managed while foundations were laid and the steel portal frame was erected.
The internal fit-out comprised plasterboard partitioning to form a number of ISO7 cleanrooms (cGMP Class C/BS 5295 Class J/FED 209E class 10,000); internal finishes including welded vinyl and the integration of three laminar air-flow cabinets; five incubators and a pass-through hatch. The construction also included forming a new metsec-type walk-on deck, to provide access to the new HVAC and electrical plant and the new automatic docking bay for egg receipt.
The HVAC systems incorporated two steam-fed air-handling units and associated extractor fans to provide air into the cleanrooms via terminal HEPAs. Active pressure control was used to maintain the required pressure regime against a varying process extract rate without compromising the classification of the cleanrooms. The HVAC systems are controlled by a new digital control system.
A new electrical distribution system was also installed, providing lighting and power throughout the facility.
A new fully automatic fumigation system was installed, including control of the HVAC system and a number of gas-tight dampers to protect unclassified areas.
The complete facility was commissioned and validated, including writing and execution of design, installation and operational qualifications.
