United Therapeutics Cleanroom Renovation and Filler Installation

Buch was contracted to install a custom-built filler, a complex machine that transfers manufactured product and loads into vials, in an existing modular clean room space for United Therapeutics. The scope included removing the clean room ceiling and walls, duct work, instrument air, electrical, and sprinkler system to accommodate the new filler equipment. Buch was responsible for receiving and rigging the filler into place in 12 sections, the heaviest of which weighed close to 2,000 pounds. Once the filler was set, Buch rebuilt the clean room around the equipment, and assisted in start-up and testing. Final finishes included re-routing of stainless welded duct with HEPA filters, installation of lights, life safety, electric, modular clean room panels, and epoxy floors.

This work was completed under partial gowning requirements while other portions of the manufacturing facility remained in service. Buch worked closely with the client in the planning phases of the project to develop an agreed upon and realistic schedule that would minimize disruption to the manufacturing operations, and ultimately get their new filler into service.

During the schedule development, Buch concurrently worked with the subcontractors to identify utility conflicts. Buch identified all utility outages that would need to be scheduled and communicated with the facility managers to ensure downstream spaces would not be impacted. Once the filler achieved factory acceptance testing, Buch was able to begin executing the work in preparation for receiving the equipment. As utilities were being deconstructed, and relocated, Buch was able to advise the owner on existing equipment conditions and make recommendations on whether or not certain components should be replaced. Our goal was to complete as much work as possible while the facility was in a planned shutdown to reduce the potential need for a future unplanned shutdown. The project finished as scheduled, and the facility was able to return to service as planned without any impact to the manufacturing schedule.

Awards
AGC of D.C. | 2021 Washington Contractor Award | Heavy Industrial