Life Sciences
Case Studies
Virology Lab Retrofit
Eichleay remodeled a virology lab by converting existing chemistry labs and office space into BSL-2 and BSL-2+ labs with support areas including ante rooms, storage, freezer farms, and autoclave rooms.
Scope Included:
- Lab planning including a detailed equipment list
- Direct access between labs and support spaces to contain biohazards within the BSL-2+ boundary
- HVAC systems modifications for virus containment and NIH BSL-2+ compliance
- Decommissioning of the solvent delivery and waste system
- Updated power and lighting
- Phased construction to minimize operational disruption
28,640 SF
of Laboratory & Offices
$26 MM
Total Installed Cost
$5 MM
Savings Achieved with Target Value Delivery
Aldurazyme (IDU) Upgrades
Eichleay partnered with the client, equipment vendors, and contractors to deliver a flexible cell culture suite capable of rapid changeover between two distinct cell culture campaigns within the same facility. The project encompassed upgrades to the cell culture room, seed lab, filtration and purification rooms, and cold storage, with a design-assist approach used for the cold room design.
A key focus was the enhancement of cleanroom environments to meet ISO 7 (Class C) and ISO 8 (Class D) classifications. Eichleay confirmed and updated HVAC systems to ensure compliance with the new process requirements, including the strategic placement and sizing of ceiling-mounted HEPA terminal units and low-wall returns to ensure proper airflow, pressure differentials, and filtration. These upgrades were critical to maintaining the facility’s stringent cleanliness and containment standards.
A target value design approach was used to meet strict budget constraints, and construction was carefully phased to minimize disruption to ongoing operations.
1,500 SF
Cell Culture Suite
$20 MM
Total Installed Cost
cGMP Engineering & Design Program
Portfolio of capital projects within eleven buildings on campus housing primarily manufacturing and associated laboratory, pilot plants, office areas, and utilities supporting manufacturing.
Project sizes ranged from $250K to over $20MM TIC including:
- Mechanical HVAC and utility upgrade projects
- Electrical infrastructure projects
- Lab and cGMP space renovations
- Addition of cold rooms and freezers
- Automation upgrades
- Warehouse renovations and office space reconfigurations
We took advantage of our in-house scanning capabilities and were able to capture 3D point clouds of existing conditions and utilize this information to prepare a 3D model of the modifications. Projects followed a stage gate process with conceptual design followed by basic / detailed design and construction support. Eichleay was responsible for upkeep of building drawings and was instrumental in assisting the client in establishing site wide master documentation.
$239 MM
Total Installed Cost of Projects
7 Years
Managing the Program
150+
Projects Executed
Project Examples from Program
HVAC Upgrades
Eichleay assisted with a campus wide project to replace 30 packaged rooftop air conditioners and 7 split system fan coil units. Existing gas fired/direct expansion (DX) rooftop air conditioners were replaced with two centralized air handlers utilizing chilled water and heating hot water. Existing packaged unit zones were then served by custom designed rooftop air terminal boxes to provide individual zone temperature control.
-40F Freezer Project
This project involved the replacement of an aging –20°C freezer and 5°C ante cold room. The new system utilized CO2 refrigeration equipment able to accommodate 100 pallets for bulk storage of GMP drug substances (with redundant systems for the Freezer and the Cold Room). This was the first low temperature bulk storage freezer completed by the client in North America.
Process Utilities Upgrades
Utility upgrade project to prepare the deionized (DI) water system for a future upgrade of the water for injection (WFI) still. Eichleay’s scope included data gathering and site verification necessary to prepare modified P&IDs, detailed piping demolition, and layout drawings depicting the removal and installation of rerouted DI water piping.
Warehouse to Manufacturing Lab Conversion
Eichleay functioned as the lab and master planning architect and design architect for a warehouse conversion project. The project included architecture, structural, mechanical, piping/plumbing, process, electrical, and instrumentation.
The project scope focused on tenant improvements to modify the existing warehouse space primarily for laboratory and office use. The project was executed in multiple phases:
- Phase 1: Warehouse conversion, including 6,400 square feet of new lab spaces with interior circulation, interior utilities, and exterior service yard development
- Phase 2: Addition of 2,800 square feet of lab space
- Phase 3: Completion of the remaining warehouse space with new labs and office spaces
The labs included cell culture engineering and process development suites, a new mechanical room, interstitial platform, new office spaces, and hallway circulation. Exterior upgrades featured improvement accessibility parking, entryway enhancements and utility yard upgrades.
34,000 SF
New Laboratory & Offices
$20 MM
Total Installed Cost
3+
Phases of Construction