Mayne Pharma’s Oral Solid-Dose Commercial Manufacturing Facility
Award of Merit
Owner: Mayne Pharma
Lead Design Firm/MEP Engineer: Middough Inc.
Construction Manager: BE&K Building Group
Civil Engineer: The East Group
Structural Engineer: Butler Manufacturing
Mayne Pharma’s 155,000-sq-ft facility includes 128,000 sq ft of operational space along with more than 27,000 sq ft of mezzanine space for critical mechanical, electrical and high-purity piping systems.
One challenge was the project site’s low elevation, coupled with a high water table. Once contractors cleared the site of trees and removed the top layer of soil, crews constructed ditches to drain water from the site. Ultimately, crews raised the entire 21-acre site by 6 feet prior to constructing the building pad.
Weather conditions also challenged the project team. During the first winter, bad weather delayed grading work by about six weeks. To mitigate adverse impacts to the project’s schedule, the contractor modified the construction sequence for erecting the pre-engineered metal building, enabling crews to begin steel erection two weeks earlier than planned.
BE&K Building Group was responsible for all process equipment purchasing, submittal reviews, receiving, unloading, staging and installation of the facility’s equipment. The project required the simultaneous installation of 24 mechanical and process air-handling units on the facility’s mezzanine level, which demanded close coordination with the mechanical subcontractor.
Overall, the new facility more than quadruples Mayne Pharma’s U.S. manufacturing capacity for oral solid-dose pharmaceutical products.