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API Project Design Build Turnkey Package for a Quality Control Laboratory
Client:
Confidential
Location:
Ireland
Project Size:
1450 sqm
Ardmac secured the Design-Build Turnkey Package for a QC Laboratory at a new API facility in Ireland, including the cleanroom envelope and a critical containment blast wall. The project featured a QC Laboratory, Filter Drier, Scrubber, Solution Preparation area, and a multi- level Process Ballroom. Ardmac led the design and construction, covering structural, architectural, mechanical, and electrical aspects. Jacobs Engineering oversaw the project, with Ardmac collaborating closely with specialist trade partners. Integrated Approach: Ardmac employed an integrated approach to ensure smooth execution, focusing on the early identification of secondary steel requirements to optimize construction and meet blast and fire ratings. The design also accounted for more than 250 service penetration points to accommodate both current and future facility needs. Blast Wall Solution: A critical aspect of the project was the blast wall. Ardmac designed and installed a multi-storey blast wall, 18 meters high and covering 1000sqm. This 50Kn/M2 blast wall met the client’s stringent safety requirements while allowing flexibility for future
process development. The design and independent certification of the wall highlighted Ardmac’s commitment to safety and quality. Coordination of Service Penetrations: Ardmac coordinated service penetrations across all areas of the project, ensuring that they were fully addressed before construction, particularly within the blast wall, which required careful planning and collaboration with trade partners. HVAC and Electrical Systems: Ardmac designed and installed the HVAC system for the QC Laboratory and its supporting rooms, integrating Air Handling Units (AHUs), extract systems, and a CAV/VAV system for safe operation. The electrical scope included the installation of distribution boards, lighting, and HVAC control systems. Cleanroom areas were equipped with specialized lighting, featuring Passive Infrared Sensors (PIRs) and a Central Battery Emergency Lighting System. Bespoke Door Interlock System: Ardmac developed a bespoke door interlock system, integrating it with Decontamination Misting Showers and Automated Door Closers. This system was tailored to the specific needs of the
facility and included a pneumatic door automation system for high-containment ATEX areas. Containment Safety: The facility was designed with high containment to safely handle OEB 5 materials. Ardmac installed lab furniture, fume hoods, chemical storage units, and Dagard walls, ceilings, and doors, ensuring minimal leakage. All penetration details were thoroughly reviewed to comply with VDI 2083 Part 19. Commissioning and Certification: Ardmac conducted rigorous commissioning and certification processes to meet the client’s safety standards, including independent containment testing under VDI 2083. Site Acceptance Tests (SATs) were developed to confirm compliance with user requirements and ensure the safe use of the facility’s systems. Conclusion: The API Project in Ireland showcases Ardmac’s dedication to safety, innovation, and excellence. Through a collaborative approach and adherence to global safety standards, the project was successfully completed, meeting the client’s requirements for OEB 5 product use and advancing pharmaceutical industry solutions.
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