GSK Ellipta

Zebulon, NC

Overview

EAS was contacted by the General Contractor in October of 2014 to provide preliminary feasibility/constructability comments and schedule information on the GlaxoSmithKline Phase III Ellipta Mechanical Room. GSK was planning to add (2) production lines for their Ellipta product. The feasibility question was centered on whether or not it would be a good application to construct the mechanical room off site in a modular approach which would assure having a very complex MER online in time. The answer was yes. EAS was brought on to the team mid-January to help complete the design and coordination of the mechanical room. Major equipment was released for purchase mid-May. The mechanical room consisted of a 16,000 square foot space.

Project Highlights

The entire structure was fire proofed with an intumescent paint, meeting the same fire ratings as the existing building and the expansion.
The roof included a 1 hr rated assembly
Roofing material matched the rest of the building expansion.
The exterior was designed to accept the Centria panels installed on the exterior of the building, matching the existing look.
The entire mechanical room shipped in (28) sections.
The manufacturing of the mechanical room began in mid-June. Completed sections were shipped the second week of
October in (8) business days.
Delivering this mechanical/electrical equipment room, utilizing an Off Site Constructed method, saved (6) weeks off the original schedule for the team.

Project Details

Three custom air handling units (7000 CFM, 7000 CFM and 65,000 CFM)
Three Desiccant dehumidification units (7000 CFM, 2500 CFM and 2500 CFM)
Three dust collectors with exhaust fans and HEPA Bag In Bag Out Filtration (1750 CFM, 550 CFM and 550 CFM @(NEGATIVE) -60” of Static Pressure). These components were installed inside a Class 2 div 2 room.
Process and Instrument Compressed Air Plant (963 CFM @ 125 PSIG)
IT Room consisting of 10 Racks, 80 kVA UPS, Cable Tray and Bus ways, Dual Cooling 25 Ton CRAC unit all in a 1 hr rated Enclosure
Mechanical and HVAC piping including chilled water, heating hot water, medium pressure (125PSI) steam, (30psi) pure steam, and compressed air. All piping requiring insulation was insulated at the factory
Plumbing – domestic cold and hot Water, hot water return, non-potable water, floor drains and FCO’s piped in and connected by on-site plumbing contractor. Fully piped in roof drain system.
Mechanical and HVAC duct work including in-duct humidifiers, reheat coils, cooling coils, fire dampers, sound attenuators, Phoenix AIR Control Valves, duct accessories, and insulation.
Electrical system, including main distribution panels, conduit, lighting, emergency lighting and egress lighting, variable frequency drives, distribution system for all equipment in the mechanical room, etc.
Controls system included all the end devices such as pressure and differential sensors, temperature and humidity sensors, control valves, actuators, etc., all tying into a Rockwell Automation BAS.
Fire protection and fire alarm
Misc. mechanical equipment included fan coil units, emergency shower/eye wash stations, steam condensate pumps, OA intake louvers, and general exhaust fans.
(2) Hour vertical fire rated structure. Utilized an Intumescent Paint System to accomplish this.
(1) Hour horizontal fire rated roof structure. Utilized a white faced, rigid mineral board system to accomplish this.
Factory installed roof system

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