Project Focus

New Build facility comprising ISO5/ISO7 Filling Suite Core , Packaging Hall, Warehouse, Coldstores and Freezers

Service

Design Team leader (Single Point Design Team)
QA/QC
PSDP
Cost Control

Value

€54 million (contract)

Design

50 weeks

Procurement

16 weeks

Build

87 weeks

Stage

Complete

Footprint

9,019 sq. m. (97,079 sq. ft.)

Project Deliverables

  • Detailed Survey and generation of BIM Model
  • 30% Design Report and Presentation
  • 60% Design Report and Presentation
  • Hazard Analysis
  • FMEA
  • Value Engineering Workshop
  • 90% Design Report and Presentation
  • Budget Cost Analysis at each Design Phase
  • PSDP and Preliminary SHW Plan
  • Statutory Compliance & Fire Engineering
  • Procurement/ Contract Strategy
  • Tender Documentation
  • Tender Clarification
  • Tender Candidate Interviews
  • Tender Analysis
  • IFC Documentation
  • Support to Site Operations
  • Snagging/Handover
  • Final Account Negotiation
  • Safety File and O&M Review

The “Biologics 2” project is largest Botox manufacturing facility in the world and the largest single capital investment that Allergan had undertaken at its time of completion. The success of the project for Allergan was the appointment of an “Outcome-Driven Multi-Disciplined Team” for this multi packaged project incorporating the manufacture of next generation Botox, successfully completed January 2015.

– Project Manager Adam Gallagher

Overview

Allergan commissioned the design, procurement and construction of a standalone dedicated Botox manufacturing facility on a greenfield site at Westport, Co. Mayo.

Taylor Group worked with a collaborative team to deliver the project from inception to Handover and Completion including project critical equipment integration into the overall facility. Overall project value $150m

Appointment

Taylor’s were engaged as a single point design team to manage the Design, Tender, Site Operations and Completion stages of the project. This required a collaborative/partnering approach between the Client, Taylors, Designers and Build Contractors for the successful delivery of the project

Engineering Services

RPS Engineering provided support for the successful delivery of the Building Services elements of the project. A full suite of building services drawings were generated including full integration into site BMS/FMS systems. Otherwise all building services were standalone build.

Health & Safety

Taylor’s also provided the services as PSDP and the appointed contractor provided the service of PSCS

Multi-Disciplinary Team

Workshops were convened post appointment to fully scope the project with Allergan Stakeholders, Global Engineering and Site Engineering teams. This multi-disciplined/multi packaged project was managed by Taylor’s in collaborative approach through all the design stages, Procurement and Site Operations and Handover/Completion process.

Project Challenges

The project had many challenges not least the integration of full Isolator technology for the filling suite. In compliance with FM requirement basements are not permitted so the Lyophilization support infrastructure was placed in an Lower Ground Floor which was self draining. We worked closely with all our design partners and Allergan’s project team to ensure the design was in full compliance regulatory requirements from the onset. Design strategies were developed for the core design including, Toxin Security Strategy, Process Flows, Building Services, Area Classifications, Pressure differentials, and integration of project critical equipment into the fabric of the core build during site operations.

Commissioning & Validation

Commissioning activities were carries out by the construction team and monitored by the design disciplines including temperature mapping, pressure profiles and particle counts in conjunction with Allergan’s site validation team.

Completion & Handover

A detailed walk down of all systems was conducted by design disciplines/construction team including handover of O&M Manuals and the Safety File.