Whether developing the next great discovery in the lab or delivering a lifesaving treatment, speed-to-market value is shared by many success stories in the life science industry. Speed-to-market is a key differentiator for life science research and manufacturing so hiring a single-source builder enables these companies to meet growing demands.

Consigli and Related Beal partnered together for the construction of a four-story structure and concurrent fit-out of R&D, cGMP and office/amenity spaces for Vertex Pharmaceuticals Cell & Genetic Therapies Facility. While the projects were managed separately with teams focused solely on delivering for their respective client, we were able to identify efficiencies benefiting all parties.

From the onset of pre-construction, we partnered with the core/shell and fit-out teams during joint scheduling meetings leading to a strong alignment of project goals, streamlined communication and early decision-making for critical building components.

Working collaboratively was critical in leveraging the advantages which included:

Early Tenant Input
Vertex was able to give input while the core/shell was being built which ensured minimal rework of building components. For instance, they chose common areas finishes to align with their overall design. This enabled informed decision making during design, reducing the need for value engineering.

M/E/P/F/P And Structural Coordination
The extensive coordination between core/shell and fit-out teams decreased a substantial amount of rework and demolition by finding structural modifications prior to installation as well as leveraging installation and tie-ins of mechanical and electrical systems. For example, we were able to have a seamless RAHU installation because we coordinated all the roof drains and tie off anchors, set slab penetrations for ductwork prior to concrete pours, and installed hangers prior to thermal spray insulation.

Design-Assist Procurement
Consigli solicited pricing for Design-Build M/E/P/FP partners during Schematic Design phase (SD) as opposed to waiting to Construction Documents (CD). Due to this strategic approach, Consigli and our Design-Build M/E/P/FP partners were able to lock in market pricing early and drive the design to a targeted value. This provided a schedule advantage for coordination of systems and upfront cost certainty. These measures allowed the ownership group to make informed decisions at an early stage in the design.

Integration of Pre-fabricated Cleanroom
The project team is prefabricating a modular cleanroom where Vertex will create its cell & gene therapies. During the core/shell construction, we were able to start the modular cleanroom earlier than normal, which will allow ample time for successful validation procedures.

Full PDF here: Driving Speed-to-Market Value as the Single-Source Builder_Consigli_April 2021

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With the increasing demand for products from our aging population, public investment is at all-time high– $1 billion in investment is forecast over the next ten years in Massachusetts alone. This industry, which formerly had plenty of options for leasable space, is actively seeking new opportunities for growth. Consigli is working on life science projects throughout the Northeast, including new development, renovations of existing buildings and tenant fit-outs.

We recently completed one such project for ImmuCell, a Maine-based animal health medicine manufacturer. We served as the construction manager to expand their Portland headquarters with a new, 16,000 SF cGMP facility for the production of a new biologic treatment of a common infection found in cows worldwide.

Immucell’s existing facility housed products regulated by the USDA; this new product requires more stringent FDA approval. The company decided to build a new facility for the product that would include space for fermentation, laboratory, processing and a storage warehouse.

As with the development of any new product, an aggressive schedule was required to have the facility up and running so they could adhere to their planned schedule for regulatory approvals; meaning the build-out had to happen over the course of 11 months.

Some of the steps taken to meet this challenging construction schedule include:

Construction began before design was complete. The cGMP facility was built in two phases. The first phase was the construction of the core and shell.  This process began in September of 2016, and completing as much as possible before winter set in was a priority.  The second phase was the fit-out, which focused on installation of production equipment and support space customized to the treatment’s unique manufacturing process. The fast-track construction schedule included major bid packages, such as high purity process piping and process control valves and automation, as well as long lead process-related equipment.

• Down-to-the-minute site coordination. To ensure there was no man-hour waste on the project, detailed coordination on site was of utmost importance. Our team utilized a number of tools and processes to expedite on-site activities:
• Technology. Utilizing BIM and 3D technologies ensured our team in the field would be able to get everything that needed to be in the space to fit as anticipated, such as making sure utilities that ran to work and lab stations fit above ceilings.
• Materials verification. When building cGMP facilities, the successful execution of the project hinges on the accountability of the team for verifying every material brought on site. In an environment where even the smallest particle can disrupt the manufacturing and fermentation process, our standard operating procedures are essential to the operation of the facility post-construction.
• Limited materials on site. Once materials were verified, there was a finely tuned schedule for materials to arrive on site so they wouldn’t be in the way of workers who needed to easily move between rooms during the fit-out stage. We also employed a “nothing hits the ground” strategy; any materials brought on site were on a cart or pallet so they could be picked up with a pallet jack or easily moved.
• Coordination between vendors and the trades. LEAN practices were used to coordinate the significant amount of coordination that must happen with vendors installing equipment, as well as between the trades. MEP contractors shared a platform staging system to ensure pipes, conduit, and ductwork installation was as efficient as possible. We did pull planning for all trades, where the foreman coordinated in each space so the next trade could begin.

The opportunity to be part of the growth and the development of companies behind pioneering research, innovative solutions and lifesaving cures, allows us to contribute to progress each and every day.

Consigli is constantly researching ways to make the construction process more efficient; from worker productivity to technological innovation. We recently embarked on a study of the daily protocols required by our workers in clean room environments; from entering the building through gowning up and other protocols. This data shows that almost one-fifth of a worker’s day can be spent on maintaining protocols; so we’re finding new ways we can minimize the time it takes our workers to begin daily tasks in clean room environments while still adhering to strict guidelines…thereby maximizing progress and reducing project schedules in the process.

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