Cyma Builders was retained by a confidential client to fit out an existing space with a 5,500 SF suite intended to support the installation and operation of a new packaging line and provide a separate 5,500 SF shell space to be used for a second line that will be installed in the future. This project involved a significant amount of structural and MEP demolition within the footprint of the new and future packaging lines to allow for the new infrastructure required to support the line. This project needed to be closely coordinated with the client, as the site of the new packaging lines was adjacent to active operations on all four sides.
The early phases of this project involved the demolition of existing MEP utilities that were positioned above labs and corridors below. Several pieces of mechanical equipment were also located above ceiling on an equipment platform with many catwalks sprawling above the space. This included an electrical mezzanine with several panelboards, security panels, and control panels. Once the demolition of existing equipment and utilities had been completed, the structural steel associated with the existing equipment platform was removed entirely. The demolition also required the tracing and removal of multiple floor drains and underground pass-throughs. A temporary partition was utilized to separate construction from an operational loading dock that was active through the duration of the project.
Once the demolition had been largely completed, the team moved into the structural portion of the project. It was discovered early in the structural phase that there was lead containing paint on many of the existing pieces of steel that our new steel was to be tied into. An abatement contractor was engaged to chemically strip the paint off the existing steel columns and beams to allow the structural steel work to continue. This involved concrete scope to install (6) enlarged footings for both new and existing steel columns to support a new electrical mezzanine and rooftop dunnage platform. Existing columns and beams also needed to be reinforced as part of the structural scope. An electrical mezzanine was constructed above what would become the new packaging line to support both existing and new electrical, security, and controls infrastructure. A dunnage platform was provided at the roof level to support multiple pieces of MEP equipment and associated piping, including but not limited to an air handler, an air-cooled chiller, two chilled water pumps, a humidification steam generator, an air separator, and multiple tanks to adequately supply the new spaces below.
One half of the 11,000 SF project footprint was left as a shell space to house a future second packaging line following the completion of demolition. The second half was fitted out with an epoxy flooring system, clean acoustic panels for sound attenuation, stainless steel wall protection including panels and bumper rail, and stainless utility chases to allow for drops down to the equipment. MEP infrastructure was provided above ceiling to support the new space and provide the required utilities to the packaging line. A cable tray system was also introduced to carry utilities associated with the packaging line from one machine to another above ceiling. A new sliding door was installed in an existing full-height CMU partition to provide access from the suite into the adjacent existing process corridor. This installation required temporary shoring of the CMU wall to allow a lintel and associated support steel for the sliding door to be installed without requiring the entire wall to be removed and rebuilt. A new high speed roll-up door was also installed leading from the suite into the adjacent existing loading dock on the opposite side of the room.
This project required several weekend crane lifts to load steel, equipment, and piping to the roof. Each of these picks needed to be closely coordinated with the site’s personnel and operations schedules. Multiple electrical and fire protection shutdowns also took place over the course of the project to allow us to perform the required demolition of existing items and integration of our new utilities into the existing system. Each of these utility shutdowns were coordinated with the client to ensure there were no unexpected interruptions or outages. A significant amount of coordination with the packaging line manufacturer was required to confirm that the correct utilities were being provided down to each machine and in the correct location to allow for proper operation.
