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Multipurpose Facility
Our firm’s initial assignment from Novo Nordisk,
a global leader in diabetes care, was for design and construction
of a two-story tilt-up wall panel multipurpose facility
at the pharmaceutical company’s Clayton site. The
facility features a full-service kitchen and cafeteria,
offices, conference rooms, training facilities and shell
space for future laboratories. This fast-track, design-build
project was completed in just eight months. Our firm self-performed
the concrete and carpentry work.
Insulin Sterile Filling Process — Conceptual
Study
Our second assignment at the Clayton site was a conceptual
study for the component prep area for an insulin sterile
filling process. The design provided unidirectional flow
of materials in a Class 10,000 cleanroom environment for
washing, sterilizing, and drying vial/cartridge combi-caps
and miscellaneous parts such as beakers, hoses, buckets
and mops. The equipment included two pass-through autoclaves,
two pass-through fluidized bed stream sterilizers, two
washers and a parts washer.
Maintenance Facility Expansion
Next our firm was awarded a design-build project for the
expansion of an existing maintenance facility and the
addition of a parallel process chiller. The expansion
included an open area containing a new water for injection
(WFI) pretreatment water system and a maintenance office.
A glass curtain wall on two sides allowed for visual access
to the equipment and interesting exterior elevations.
For this third assignment at the Clayton site, our team
coordinated with Novo Nordisk’s plant operations
to relocate and shut down multiple underground utility
lines. The parallel process chiller installation included
approximately 350’ of process chilled-water piping,
refrigerant tubing and glycol feed make-up piping.
Expansion 2003 Project
Our fourth assignment was for multifaceted design-build
project designated “Expansion 2003.” This
project encompassed a 32,000 sf two-story insulated metal
panel addition to house the offline inspection rooms,
conditioning rooms, a cold room that maintains a temperature
of 4°C, locker rooms and shell space for second floor
labs/office. The original scope of work grew to include
the addition of a metrology lab and office upfit. General
sitework included parking, access roads support areas
and sidewalks, and the relocation of extensive underground
utility piping.
The 6,800 sf metrology lab was designed and constructed
in the existing second story shell space. The lab includes
space for the calibration for temperature, humidity, vacuum,
conductivity, resistivity, general electrical and gas
flow. Included in the shell space were a conference room,
office, storage room and mass testing room.
Insulin Manufacturing Facility Expansion —
Conceptual Study
Our fifth project at the Clayton site entailed programming,
conceptual design and estimating for an expansion of Novo
Nordisk’s existing insulin manufacturing facility
on site. The 120,000 sf expansion included an additional
sterile fill vial line, a new FlexPen® medical device
facility, new semi-finished and finished cold storage
areas, which maintain a temperature of 5°C, relocation
of two existing packaging lines, a new packaging line
and associated conditioning rooms. The addition also consisted
of a new ambient raw material warehouse and loading docks,
a 48-hour ambient hold room, three offline inspection
rooms, new locker/gowning facility, production offices
and mechanical space.
Our firm’s sixth project at the Clayton site was
the construction of a 50,000 sf warehouse and utility
building. The project included approximately 8,500 sf
of cold storage space that maintains a temperature of
5°C, and high density racking system. In addition,
the project included ambient storage, material staging,
pallet washing and loading docks. The structure consists
of a steel frame with insulated metal panels. The utility
area — housing two chillers, two emergency generators,
a utility transformer and four cooling towers —
serves the warehouse, as well as the existing facility.
FlexPen® Facility
Our seventh assignment from Novo Nordisk called for managing
construction of the company’s FlexPen facility,
which manufactures pre-filled insulin pens. According
to Novo Nordisk leadership, this latest expansion at the
Clayton site enables the worlds’ largest insulin
supplier to meet increasing demand of insulin analogs
in the U.S. diabetes market. The scope of work for the
FlexPen project included a 10,500 sf area for assembly,
10,500 sf of packaging space, an 8,100 sf cold-storage
area that maintains a temperature of 5°C, and a 6,800
sf area housing ambient storage, conditioning rooms, gowning
rooms, laboratory space, and various support areas.
The two-story, 37’ high building was constructed
using a conventional steel frame with insulated metal
panels. Utilities included clean low-pressure steam, hot
water, chilled water, compressed air and vacuum air. The
HVAC system required eight air-handling units supplying
approximately 235,000 cfm.
The BE&K Building Group’s project team was able
to erect all of the above-grade construction for this
facility in just six weeks. A groundbreaking ceremony
for the final phase of construction of this milestone
project was used as an opportunity to celebrate Novo Nordisk’s
U.S. growth as well as its Danish heritage. Attendees
included both the U.S. Ambassador of Denmark and
Denmark’s Ambassador to the United States. |
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Novo Nordisk Building Program
Clayton , North Carolina
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| Project
Location |
Clayton,
North Carolina |
| Construction
Value |
Multipurpose
Facility —
$3 million
Insulin Sterile Filling
Process Conceptual
Study — Confidential
Maintenance Facility
Expansion — $780,000
Expansion 2003 —
$7.2 million
Insulin Manufacturing
Facility Expansion
Conceptual Study —
Confidential
Warehouse/Utility
Building — $13 million
FlexPen® Facility —
$22 million |
| Building
Size |
Multipurpose
Facility —
22,000 sf
Insulin Sterile Filling
Process Conceptual
Study — 400 sf
Maintenance Facility
Expansion — 2,300 sf
Expansion 2003 —
32,000 sf
Insulin Manufacturing
Facility Conceptual
Study — 120,000 sf
Warehouse/Utility
Building — 50,000 sf
FlexPen® Facility —
Project — 130,000 sf
Assembly Area —
10,500 sf
Packaging Space —
10,500 sf
Cold Storage Area —
8,100 sf
Support Areas —
6,800 sf |
| Completion |
Multipurpose
Facility — 1998
Insulin Sterile Filling
Process Conceptual
Study — 2000
Maintenance Facility
Expansion — 2002
Expansion 2003 — 2004
Insulin Manufacturing Facility Conceptual
Study — 2004
Warehouse/Utility
Building — 2005
FlexPen® Facility — 2006 |
| Assignment |
Multipurpose
Facility — Design-Build
Insulin Sterile Filling
Process Conceptual
Study — Case Study
Maintenance Facility
Expansion — Design-Build
Expansion 2003 —
Design-Build
Insulin Manufacturing Facility Conceptual
Study — Case Study
Warehouse/Utility
Building — Construction Management
FlexPen® Facility — Construction Management
at Risk |
| Client |
Novo
Nordisk |
| Architect |
Multipurpose Facility — BE&K Engineering
Insulin Sterile Filling
Process Conceptual
Study — BE&K Engineering
Maintenance Facility
Expansion — BE&K Engineering
Expansion 2003 — BE&K Engineering
Insulin Manufacturing Facility Conceptual
Study — BE&K Engineering
Warehouse/Utility
Building — O’Brien /Atkins Associates,
PA
FlexPen® Facility —
O’Brien /Atkins
Associates, PA |
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