DCBA completed these two projects for Shire/Takeda to install a new cGMP compressed air system and two new 25,000-lb fan wall units. For the compressed air system, installation required new steel dunnage, a custom-made enclosure to house all the MEP components, new fire protection means, and several critical utility feeds. When installing the fan wall units, preconstruction was performed while the building was occupied and included installation of new steel dunnage and platforms on the rooftop, relocation of utilities, and rigging of the new units into place.
Both projects utilized brief facility shutdowns, extensive balancing, and 24/7 construction to ensure that the spaces were fully commissioned and the projects successfully completed.
Sanofi hired DCBA to convert a preexisting 5,125-ton chiller plant that served various cGMP pharmaceutical HVAC and process needs to a variable speed arrangement. To do so, VFDs were utilized to control chilled water pumps and allow for more dynamic load balancing. In addition, this project required the installation of a new cooling tower, differential pressure, wet-bulb temperature plant instruments, and a chemical feed system, as well as the reconfiguration of sand filter backwash piping and controls and usage of Reverse Osmosis Reject Water for cooling tower make-up. DCBA modified the chiller plant’s control sequences and operation parameters, and consolidated plant-wide BMS chilled water data to a central location.
This three-and-a-half-year endeavor required careful planning and meticulous coordination with Novartis’s design team and numerous equipment vendors. DCBA completed MEP, infrastructure, and architectural upgrades to an existing laboratory space converted into a new compound bank laboratory. The phased project posed two major challenges- firstly, it was imperative that work did not impact the existing, adjacent compound bank, and secondly, because the new compound bank included custom European equipment, DCBA had to be in continuous communication with equipment vendors to ensure that the correct MEP infrastructures were in place before equipment arrived on site.
Additionally, DCBA worked closely with the design team to make sure that code requirements were met, created a fully equipped research laboratory and custom cold room with automatic robots, and installed a custom FM Fire Protection System in the Tubestore Equipment. DCBA returned to make modifications as design plans were altered and performed commissioning, and assisted in the SAT final acceptance testing before moving onto the final phases, which included the demolition and removal of the original compound bank equipment.
The sequencing of this multi-phased, 16,000-sq. ft. roof replacement project relied heavily on coordination with MIT Building W7 occupants and MIT Facilities. Phase 1 work began with MEP trades starting ahead of the roofing crew to make safe equipment. The roof demolition and abatement team followed behind, removing the existing roof and then installing new blocking as needed, new drains, and the new roof with the appropriate tapers.
Scope for the penthouses required the repair of stucco siding, the removal of old windows, and the replacement of flash around skylights. On the Main Center Roof railing system, DCBA removed old wood, refurbished the paint on the steel, and added new wood and an extended cap. While this work was underway, a team replaced metal trim and flashing at the perimeter edge, penetrations, and equipment curbs.
This multi-phase roof renovation project in Downtown Boston was completed within two years. DCBA’s greatest challenge with this undertaking was that the scope of work spread across two fully occupied city blocks and crossed multiple high-rise buildings. Given the proximity of other buildings, streets, and pedestrians, DCBA coordinated construction efforts with the owner, design consultant, and the City of Boston. Such harmonization was carried out through regular communication, weekly scope review meetings, review of constructability and details, survey of existing conditions, phasing, cost, and logistics studies. Work was divided into 15 separate phases/areas, many of which were completed simultaneously. Renovation included removing old roofing membrane and insulation, installing a new roofing system, aluminum standing seam panels, flashings, stairs, windows, and sealant, and limiting the plumbing scope to accommodate the new system.
DCBA installed a 350 ft above ground high pressure steam and condensate line, part of Genzyme central utility system that feeds the entire campus. From a belowground vault, the new line went above ground next to the high voltage electrical line, passed wetlands, a storm water basin, and crossed the road by laying on the newly erected pipe bridge.
This project required preparation work from developing a project specific QA/QC plan, installing a high voltage line cover, and protecting wetlands. The project included erosion control measures, vacuum excavation, restoration of existing storm water basin, tree planting to screen the new steam line, and placement of special New England Conservation Wildlife Seed mix. The project team managed heavy pedestrian and vehicle traffic, and maintained 24-hour egress for emergency situations and tracking deliveries that support manufacturing processes.
For this project, DCBA expanded the client’s diesel and glycol infrastructure by installing new fuel storage tanks. This project was undertaken in an occupied and active pharmaceutical manufacturing plant and involved the replacement of the existing tank with an updated 10,000-gallon tank. Workers were required to bring existing systems up to code, refurbish pumps, and provide overflow sump tanks. Additionally, the project also included the installation of a new 40,000-gallon tank for the building’s glycol cooling system and the division of the existing hot/cool tank. The original tank was modified and repaired in order to make the system more efficient.
Novartis hired DCBA to simultaneously renovate a glass wash laboratory and modify the existing tempered water system in an occupied and operational space. The glass wash renovations required the demolition of existing space and features, including partitions, steam/water/RODI/tempered water piping, and HVAC items. The space was reconfigured to accommodate two large Miele Professional Glass Washers, epoxy flooring, a specialty FRP for the wall covering, water/mold resistant ceiling tile, and stainless furnishings to ensure that the space would be 100% water resistant.
Updating the tempered water system involved installing new tempered water return for the building’s emergency eyewash/shower stations. Final tie-ins required sanitization and a shut-down of the emergency eyewash system, making clear communication with facility managers and building occupants crucial. Shutdowns had to be scheduled in advance and planned for weekends or off-hours.
DCBA performed construction in this occupied laboratory space for Novartis. This project required the upgrade of existing fire suppression and the fire alarm system, as well as associated coordination. Due to highly flammable solvents used in the research lab fume hoods, it was requested to install a specific fire suppression system in each of the 64 existing fume hoods, located in 4 different labs and 2 separate buildings. In order to minimize destruction of end users and impact ongoing research, the work was sequenced in phases and planned based on end users’ preferences. Progress reports with schedule updates were provided by the project team on a daily basis to ensure the project stayed on schedule.
DCBA has managed construction services for Sanofi’s cGMP manufacturing and research facilities for nearly a decade. Over this period, DCBA has managed shutdowns in multiple buildings throughout Sanofi’s Framingham campus, never missing a start-up date. Shutdown scope has included general maintenance and calibration of in-house equipment and utilities, installation of cGMP equipment, and critical infrastructure upgrades. In addition to coordinating and managing this work (often on a 24/7 schedule)e, DCBA has also coordinated the start-up and validation of equipment within incredibly tight windows. The success of these shutdown is directly tied to the time and energy that the DCBA project team devotes to pre-planning schedules, logistics, execution, and risk mitigation.
The Exelon Corporation hired DCBA to repurpose and install a hoist next to an operating power plant. Since the hoist had been used in another facility, it was crucial that workers thoroughly reviewed all materials before beginning the project to make sure the complete system was viable. DCBA and its subcontractors had to meet Exelon’s strict safety standards, which involved intricate coordination with the Facilities Department to make sure day-to-day operations continued without interruptions. The project scope included building five new steel platforms and helical piles to support a new concrete slab for the hoist and coordinating various trades to make sure structural and electrical improvements were made efficiently.
DCBA installed new PK boilers to provide heat for the US Operational Headquarters for Takeda at their Lexington location. An existing boiler was removed and disposed of as part of the project. In conjunction with boiler demolition and new boiler installation, DCBA re-worked an existing horizontal exhaust to serve 3 boilers, connected vertical exhaust for 2 boilers to a new common exhaust, installed new IPVB exhaust fan, and refilled the boilers for line stop and valve replacement. Also provided was a full, two-component, epoxy coating of the entire mechanical room floor, replacement of rubber stair treads and risers for both sets of mechanical room stairs, and demolition of existing flue and associated CMU patching.