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PROJECT DESCRIPTION
ADCO completed this upgrade project for Merck Sharp & Dohme's bulk Tabletting room production facility in Swords. The refurbishment included the complete replacement of ceilings and the upgrade of clean room walls in the facility's first and ground floor production areas.
Challenges Faced
- Development of as-built drawings for each area was necessary to accommodate pre-manufacturing of the clean room panels.
- Works were carried out within a clean room environment beside live equipment. Risk assessments, approved method statements and a strict permit system were employed to maintain a safe and controlled environment.
- The overall project included two shutdown periods, which required careful micro-management and coordination. ADCO were extensively involved in coordination meetings 10 weeks in advance of each shutdown, which took place in April and October respectively.
- Construction man-hours peaked at over 8,000 for the two shutdowns with no accidents reported on site.
- Close proximity to live production areas during the shutdown meant that the works were carried out during restricted working times to minimise disruption.
Technologies
- A walk-on clean room ceiling was installed and included new ATEX rated lights, electrical and HVAC installations.
- A pre-manufactured component clean room panelled system was adopted by ADCO allowing for fast installation on site to ensure programme dates were met.
Successes
- The project was completed on time and within budget with no reportable accidents, including during the intense shutdown periods.
- The high standard of finish on this build exceeded the client's expectations and complete works met their objectives.
- Over the course of the project ADCO developed a good relationship with the client. As a result of this ADCO have now secured a place as one of Merck Sharp & Dohme's framework contractors.
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