May 13, 2024 1:36 pm Published by

Project Dunbrody – Integer Facility Expansion

Project Details

Project Sector/s:
Pharmaceutical
Client:
Integer
Architect:
TOT Architects
Project Manager:
BeMRA
Consultant:
Varmings
Main Contractor:
DFL
Project Value:
8 million

Project Scope:

Project Overview
The expansion of the Integer facility at Project Dunbrody exemplifies Tritech’s commitment to enhancing efficiency and accuracy while minimising time and budget expenditures through off-site manufacturing. Tritech’s in-house BIM team has effectively utilised LEAN principles and Modern Methods of Construction (MMC) to facilitate an early project handover. The new 2-storey development adds 4,500m² of advanced production and office space, incorporating a 580m² Coater extension and significant refurbishments to existing structures, including the provision of HVAC for an ISO Class 7 Cleanroom. By prioritising off-site manufacturing, the project adheres to strict NZEB and Part L Building Regulations, ensuring sustainability and energy efficiency are at the forefront of development. This approach not only meets but surpasses the complex demands of the pharmaceutical manufacturing industry.

Mechanical Scope
Tritech was tasked with the supply, delivery, installation, testing, and commissioning of comprehensive mechanical services installations including:
- LPHW Heating system with Air Source Heat Pump and LPG fired Boiler Plant
- HVAC for ISO Class 7 Cleanroom
- Advanced Mechanical ventilation systems and Air Handling Units
- Air cooled chiller and four pipe fan coil unit installations
- Extensive Domestic water services and Above ground soils and waste systems
- Compressed air and process gases systems
- BMS/MCC and controls installation
- Implementation of various fire fighting and protective systems

Client vision/objectives:

Integer's strategic expansion is designed to substantially increase its capacity for high-volume guidewire and wire-based manufacturing. This includes an investment in a new R&D and manufacturing facility in Galway, Ireland, where Tritech is also delivering the electrical services. This expansion is focused on providing localised solutions for structural heart, neurovascular, and electrophysiology applications, facilitating seamless transitions from R&D to operations.

Unique challenges of the project:

The project required a phased handover with early individual services handover to accommodate Integer’s operational needs. Tritech addressed these challenges by utilising offsite fabrication techniques. For example, the plantroom was pre-constructed offsite and pre-commissioned, which accelerated the construction schedule. This approach not only improved safety and quality assurance but also reduced the onsite labour force and minimised site waste.

Tritech Methods/Innovations:

Tritech’s engagement strategy involved close collaboration with Integer's team to thoroughly understand and meet their specific needs. Our in-house BIM team and application of LEAN principles facilitated early handover schedules, demonstrating Tritech's commitment to delivering client-focused solutions using Modern Methods of Construction. These practices significantly enhanced project efficiency and sustainability, showcasing Tritech's ability to adapt and innovate in complex project environments.