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MSD Biotech | Jacobs : Fit Out or Refurbishment Over €30m

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Category: Fit Out or Refurbishment Over €30m
Project: MSD Biotech Dublin
Contractor: Jacobs
Client: MSD Biotech Dublin
Engineer: Jacobs
Architect: Jacobs

This project entailed significant retrofit works within the existing MSD Biotech facility in Swords, Co. Dublin with the objective to introduce a new production process. The new facility will play a pivotal role in the manufacture of MSD’s biologics-based medicines, including in the area of immuno-oncology, and will expand MSD’s current internal network of biologics drug substance manufacturing plants.

The project included construction of a new warehouse with main entrance, extensive works to convert to a bulk drug substance building, removal of existing façade and installation of new façade to CUB buildings with other ancillary buildings, all tied in to existing buildings on site.

As contractor Jacobs’ scope included the engineering, procurement, construction management and commissioning of the works within a defined operational shutdown window.

There were many exceptional characteristics of this retrofit delivery, including:

  • Exceptional levels of pre-planning and risk management
  • Zero TRIR (Total recordable incident rate) from 350,000 site hours
  • High levels of OSM (Off Site Manufacturing) to eliminate potential for site safety and quality issues
  • Project delivered within 0.5% of budget
  • Focus on quality that yielded defect-free delivery of 85% of mechanical systems – less than 1 punch per system
  • The design was done remotely during Covid
  • Handover of 182 systems with no interruption to operations

Kirby Engineering & Construction were responsible for the installation of all electrical services at the facility’s CUB (central utilities building), manufacturing, science & technology lab, warehouse, fallow fit-out and external locations.

They availed of off-site fabrication to ensure that the project was delivered on schedule and to the highest safety and quality standards. The project dimensions encompassed 12,000m² taking all scopes into account with an average of 80 Kirby trades on site.

Kirby was responsible for the mechanical and electrical scope of works. The electrical systems installed by Kirby included:

  • MV Distribution
  • LV Distribution
  • Generator
  • UPS
  • General and Emergency Lighting
  • General Service Power
  • Mechanical Plant Service Power
  • Fire Detection and Alarm
  • Access Control, Intruder and CCTV
  • Earthing and Bonding
  • Containment of Voice and Data Distribution
  • Lightning Protection
  • Impulse Tubing – Gas detection system
  • The mechanical systems installed by Kirby included:
  • Chilled Water
  • Low Temperature Hot Water
  • Laboratory Gases
  • Smoke and Heat Exhaust Ventilation
  • Supply and Extract Ventilation Distribution
  • DWS
  • VRF Air Conditioning
  • Server Room Air Conditioning
  • Bioprocess Waste
  • CO2
  • Deionized Water
  • Humidification Water
  • Nitrogen
  • Oxygen
  • Process Air
  • Compressed Air
  • Instrument Air
  • Process Waste
  • RO Water
  • Steam
  • Soils and Wastes
  • Domestic Water Services
  • Plastic Exhaust
  • Stainless Exhaust

Installed plant items include MV/LV Switchgear, MV Cable, Generators, Air Handling Units, Parts Washer, Incubators, Run Around Coil, Fume Hoods, Clean Steam Generator, RO Skid, Autoclave, FCU’s, Tanks, Calorifier, Condensate Recovery Units, Extract Fans, Fire Dampers, Fire Damper Control Panel, VAV’s, Unit Heaters, Lab Gas Tap Ceiling Panels, Rainwater Downpipes – HDPE Pipe (Fusion Welded) / Vent Pipes – George Fischer (Fuseal).

The total project meterage consisted of:

  • 360,000m of cable
  • 18,000m of containment
  • 150 no. of calibrations

RTC – Innovation Drainage Solutions were contracted to design, supply and install double contained polypropylene chambers, pump stations, pipework, stainless-steel gullies and stainless-steel channels across all areas of the new build. They also supplied stainless steel floor drains and installed gravity rainwater systems to the project.