New Albany Pharmaceutical Manufacturing Expansion
Project Overview
Sauer Group was selected as the Design Assist partner on this 290,454 square foot process facility and lab complex for this confidential pharmaceuticals facility in New Albany, Ohio. This large-scale project required extensive preconstruction services and sophisticated mechanical systems to meet stringent cGMP requirements.
The project demanded a collaborative approach from the earliest design stages, with Sauer Groupbproviding critical input on constructability, cost management, and system optimization throughout the development process.
Square footage
290,454 SF
Contract value
$29M
Completion
Jun 2023
sector
Pharmaceutical
Early achievement
cGMP Validation
Delivery method
design assist
Construction mgr
Turner
Construction
Reference contact
Bruce Carder, Turner Construction, 614-984-3000
The Challenge
- Budget Constraints
The project was over budget during both the Schematic Design (SD) and Design Development (DD) stages, requiring innovative value engineering solutions without compromising the facility's functionality or regulatory compliance requirements. - Complex Systems Integration
Installing and coordinating large-scale mechanical systems including air handling units, chilled water plant, boiler plant, and extensive process piping networks within a pharmaceutical-grade environment. - Early Validation Requirements
Meeting aggressive cGMP validation timelines required exceptional quality control and documentation throughout the construction process.
The Sauer Group Solution.
Design Assist Partnership
As the Design Assist partner, Sauer Group provided comprehensive preconstruction services from project inception, offering real-time feedback on design decisions and their impact on constructability and budget.
Value Engineering Excellence
When the project exceeded budget parameters during early design phases, Sauer Group developed and presented alternate solutions that successfully brought the project back within budget while maintaining all critical performance requirements.
Rigorous QA/QC Implementation
Sauer Group implemented a thorough Quality Assurance and Quality Control system that ensured all installations met pharmaceutical industry standards and facilitated early cGMP validation, saving valuable time in the facility commissioning process.
The Challenge
Our comprehensive preconstruction involvement included:
- Design Assist: Collaborative design development with the project team
- BIM Coordination: Full 3D modeling and clash detection
- Value Engineering: Cost-saving alternatives without compromising quality
- Constructability Reviews: Identifying and resolving potential field issues during design
- Scheduling: Detailed construction sequencing and timeline optimization
- Estimating: Accurate cost projections throughout design development
- Prefabrication Planning: Strategic planning for off-site fabrication opportunities
- Equipment Input: Technical specifications and selection assistance
Systems Installed
The mechanical scope encompassed:
- HVAC Systems
- Large-scale air handling systems designed for pharmaceutical environments
- Specialized filtration and air quality control
- Environmental monitoring and control systems
- Central Plant Infrastructure
- Complete chilled water plant installation
- Boiler plant systems
- Associated pumping and distribution networks
- Process Piping
- Extensive process piping networks throughout the facility
- High-purity piping systems
- Process utility distribution
- Plumbing Systems
- Complete plumbing infrastructure
- Specialty systems for laboratory and process areas
Key Achievements.
Budget Recovery
Successfully brought an over-budget project back within financial parameters through strategic value engineering.
Early cGMP Validation
Thorough QA/QC processes enabled the project team to achieve early cGMP validation, accelerating facility startup.
Design Collaboration
Provided critical design input that improved constructability and reduced field conflicts.
Schedule Performance
Met all project milestones despite the complexity of the pharmaceutical facility requirements.
More of our Projects.
Delivered multi-phase mechanical construction for large-scale mission-critical data center facility, including advanced cooling systems, industrial piping infrastructure, and prefabricated MEP solutions under aggressive schedules.
Upgraded the medical vacuum system for the new Wexner Medical Center, installing new risers and branch lines, area alarm systems, and connections to zone valve boxes, integrating with existing infrastructure and completing all work while the hospital remained fully operational.
Large-scale mechanical construction for a confidential 3,000,000 SF hybrid/electric vehicle battery manufacturing facility, including plant cooling infrastructure, refrigeration systems, and welded industrial piping.
