Project:
Merck, Elkton, Virginia
The Challenge:
ColonialWebb Contractors provided HVAC, plumbing and piping for an expansion to the Merck pharmaceutical production facility. The scope of our contract called for:
- A finished goods staging area
- A finished goods warehouse
- A mechanical support area
- A mechanical penthouse.
Due to the nature of the company’s business, we worked within tightly controlled parameters for hygiene and security.
Our Approach:
To condition the new spaces, ColonialWebb installed and piped a 400-ton chiller along with three air handling units and associated ductwork. The project included an exhaust system for the production and storage areas. Since environmental contamination is a concern, we provided a new HEPA bag-in-bag-out unit to complement the exhaust system.
For comfort heating, we placed a complete hydronic hot water system that used a steam heat exchanger feeding the reheat coils. The plumbing portion involved a new automatic pallet wash area for decontamination and plumbing to support the mechanical penthouse.
To guarantee cleanliness, our teams wore coveralls, disposable booties, and hair and beard covers. We often were required to change booties and sanitize our hands to minimize cross contamination when moving from one department to another. We’re used to working in conditions like this where cleanliness is of utmost importance.
Along with the understandable emphasis on purity in the production areas, Merck also introduced strict measures. These measures ensured that workers did not inadvertently export antibiotics out of the facility on their clothes, for example.
Our ability to fabricate ductwork and piping at our Richmond, Virginia, manufacturing plant enabled us to minimize costs and accelerate the project schedule. Our detailing team’s ability to coordinate all utilities proved vital in avoiding conflicts with other contractors and in demonstrating to Merck another dimension of our expertise.