The Works comprise the construction of an Advanced Technology Unit, for an internationally traded pharmaceutical contract packaging, storage and distribution company. The building is 8230m2 (including 3,300m2 of cleanroom), and works include all ancillary car parking, bicycle parking, loading areas, landscaping, internal roads, ESB Substation, drainage and ancillary works on a site of 2.93ha within the overall lands of IDA Dundalk Science and Technology Park at Mullagharlin, Dundalk, Co. Louth.

Due to Client licensing requirements a phased build was required to achieve early Client use of the facility via early delivery of the clean room section to the nominated clean room contractor.

The first phase was to have the cleanroom and warehouse areas complete within 10 months of commencement of works. The office area was complete 1 month after the first phase.

Key Packages

• Groundworks, including excavation and creation of BERM to site boundary, Drainage, Street Light, Electrical Ducting and watermain installations. Concrete Pad and Strip Foundations, approximately 450m3 of concrete installed.
• Insitu Concrete – 7500m2 of insitu concrete floor slab 150mm thick, to a Class U3 fair level surface finish. 1500m2 300mm Precast Floor slabs installed to first floor areas with concrete screed installed to FM2 standard. 1100m2 300mm Precast slabs to Roof with concrete screed installed.
• Blockwork – 200m2 of blockwork to Substation. 1920m2 of 215mm blockwork to Internal walls, including all necessary accessories (U-Blocks, Lintels, DPC’s, reinforcement)
• Structural Steel Work included 870 tonnes of primary and secondary steel including columns, beams, roof members including parapet posts and roof trusses and Sundry items including bracings, framing, trimmers, gutter brackets, holding down assemblies, and sheeting rails/purlins.
• Full Office Fit Out (1600m2) to Ground Floor and First Floor including Male/Female Changing Rooms, Male/Female Toilets, Canteen Area, Offices, Conference Room and First Aid Room which included the following finishes: Stud Partitions, Floor Finishes, internal Joinery, fire doors, skirtings, glazed partitions.
• APS Curtain Wall System installed
• External Wall Cladding – Kingspan RW Panel (KS1000RW) 2407m2 – This was placed to the Rear Elevation of the building and Parapet Walls. KS1000 MM – Mini Micro Insulated Wall Panel, 100 mm panel thickness, 2,490m2 – This was completed to all other elevations of the building. Kingspan BENCHMARK Evolution Panel, 100 mm panel thickness = 134m2
• Roof Cladding – Kingspan KS1000 RW = 3,410m2 completed to High level roofs. Kingspan KS1000 TD Topdek, insulated roof panel; 91 mm core thickness, 3,300m2 was completed to lower level roof.
• Mechanical Fit Out including 5nr AHU’s including associated accessories and big foot mounting system and 750 metres of Ductwork
• Electrical Fit Out including Biometric Access Controls
• ESB Substation approximately 35m2 Floor area, including all necessary trenching and construction to ESB specification. MV Switch Traffo and associated works also were completed.
• Clean Room was completed by a separate Contractor Bassire, where Kilcawley Construction coordinated the sequencing of works to be completed.
• Car Park Area completed to hold approximately 170nr cars. Car Park including access routes around the building is approximately 10,000m2. Slipform Kerbing was also installed.
• Landscaping completed by Douglas Nurseries for Kilcawley Construction which included 250 metres of Post and Rail Fencing with Sheep wire to boundary, 4800m2 cultivating/raking and seeding, 1250nr of Hedging plants and 45nr Tillia cordata trees.

Key Deliverables

• Project involved the Management and coordination of multiple sub-contractors on a building contract of similar scale, nature and complexity
• This project was constructed from site commencement within 11 months. The first phase to allow client fit out of the cleanroom and warehouse areas was completed and commissioned within 10 months.
• Advanced Technology building for a high tech client
• The project value €17,000,000.00 delivered in 11 months.
• Total area of the new facility is 8,230 square metres.
• Significant and complex M&E installations and integration
• The project was delivered on time and to budget and to the satisfaction of the client.
• Project delivered under BCAR
• Multi-storey
• Building air permeability of 3.00 (M³/hr) /M² @ 50 Pa Building Pressure
• Car Parking
• Site Works, including the provision of new access road, set down and pick-up areas, perimeter fencing and landscaping.
• Use of prefabricated components – Structural Steelwork; aluminium windows and doors, precast concrete, stairs, floors, terraces and walls; prefabricated internal wall panels; insulated external roof and wall panels

Awards

Short listed for ICE Awards 2020 –Category: Industrial Over €10 million

Upgrade existing plant in eight different zones in a live manufacturing environment, including demolitions, process drainage, cleanrooms. Mechanical and electrical services, lab equipment and specialist floor finishes.

Key Packages

• Clean room walls & ceilings.
• Floor finishes.
• Mechanical & electrical services.
• Process drainage.

Key Deliverables

• Working in 24/7 medical production facility.
• Environmental management and dust control key factor.
• Integration of mechanical and electrical services within existing services.
• Phased work in eight different zones.
• Cleanroom 10,000 and 100,000 class.

First phase consisted of the refurbishment of an existing building for office/labs. Second phase consisted of the construction of a central utilities building. mThird phase consisted of the construction of a canteen area to service both buildings.

Key Packages

• Piling – 390nr 450 diameter CFA piles.
• Groundworks – drainage & ducting laid around existing services.
• Cladding – alucobond cladding.
• Glazing – specific thermal targets required.

Key Deliverables

• Existing live pharmaceutical plant.
• Separation of existing services to provide stand alone infrastructure for Alexion from neighbouring plant, ensuring plants were kept live at all times.
• Multi stakeholder site, integration and liaison with all stakeholders.

The Alexion Turning Circle project consisted of transforming the green area to the North of the Alexion campus into a car park and truck turning circle. The car park added 12 new parking spaces, 8 new E-charging spaces to the facility along with much needed truck turning space.

Key Packages

Groundworks, Water Main Diversion, Kerbing and Paving, Blacktop surface finish, Linemarking.

Key Deliverables

Accident and Incident Free
All excavations completed around known and unknown underground services
Project completed on time and to a high standard
All works were completed within a live facility and all transport and pedestrian access routes were maintained throughout the duration of the project.

The construction of a 3 story high Biologics manufacturing facility. The substructure consisted of piling, drainage, ducting, RC Concrete. The CSA works consisted of the fitout of the building where an office area, warehouse and multiple plant rooms were created.

Key Packages

Substructure: Piling, Drainage, Ducting, RC Concrete
CSA: Partitions and Ceilings, Vinyl and Tiling, Epoxy Flooring, Painting, Architectural Steelwork and Fireproofing

Key Deliverables

Accident and Incident Free
Working in a live pharmaceutical production facility
Integration with mechanical and electrical subcontractors

The works consisted of the fitout of the level two of the Biologics Manufacturing facility. The works were completed within a live manufacturing environment. Works included demolition, partitions and Ceilings, RC concrete works (externally), floor finishes, cleanroom construction.

Key Packages

Demolition, Partitions and Ceilings, Floor finishes, Painting, R.C Concrete, Cleanroom construction.

Key Deliverables

Accident and Incident Free
Working in a live pharmaceutical production facility
Integration with mechanical and electrical subcontractors
Environmental management and dust control key factor

The works consisted of the fitout of multiple office spaces within the CUB Building, Fill Finish Building and Biologics Building. All works were completed within a live facility.

Key Packages

Demolition, Partitions and Ceilings, Mechanical and Electrical, Joinery, Painting and Floor Finishes

Key Deliverables

Accident and Incident Free
Working in a live pharmaceutical production facility
Integration with mechanical and electrical subcontractors
Environmental management and dust control key factor

Extension of newly completed Advanced Technology building including the enlargement of the site boundaries to the northern and western boundaries, provision of additional carpark spaces and mechanical and Electrical plant to facilitate the new building.

Key Packages

• Mechanical and Electrical installations and alterations
• Steel frame, roofing and cladding
• Partitions and ceilings
• Curtain Walling
• Glazed partitions
• Resin floors
• Vinyl and carpet floor covering
• ESB Substation and control room to ESB spec.

Key Deliverables

• Construction of Cleanroom for manufacture
• Connection of underground services while maintaining existing live services
• Complex Mechanical and Electrical integration and installation
• Installation of loading bays with integrated dock levellers
• Super flat floors for warehouse

The construction of a 3-storey healthcare manufacturing facility with structural steel-framed super structure, architectural  Kingspan wall cladding, aluminium curtain walling, structural glazing, clean room construction and building fit-out.

Key Packages

• Piling.
• Structural steel.
• Cladding and curtain walling.
• Clean room construction.
• Building fit-out.

Key Deliverables

• Fast build programme.
• Delivered under construction management.
• Working in live pharmaceutical production facility.
• Integrated environmental strategy.
• Traffic management plan to control live building site.
• Integration with mechanical and electrical subcontractors.
• Cleanroom 10,000 class (US Federal Standard 209E).

Extension to existing production facility. The building envelope is steel frame with insulated cladding and roofing. The internal fit-out included cleanrooms, gown-up areas, corridors, welfare facilities, office areas and plant rooms. The external works include all new services, car-parking, hard and soft landscaping, an ESB substation and perimeter fencing.

Key Packages

• Mechanical services.
• Electrical services.
• Cleanroom construction.
• Structural steel frame.
• Cladding and roofing.

Key Deliverables

• Key Deliverables
• Fast build construction – 24 weeks.
• Work to adjacent live production facility.
• Service tie-ins with existing production facility.
• Integrated environmental plan.
• Traffic management plan.