Cleanroom for Injection Moulding, Ross-On-Wye

Monmouth Scientific

Background

We work regularly with Monmouth Scientific and were delighted to be chosen as their partner for this new cleanroom for Meadex, specialists in injection moulding.

Requirement

Meadex needed a new cleanroom to ensure their production meets product specification and regulatory guidelines. It required personnel doors and a sliding door for ease of access. The cleanroom is split into three separate rooms measuring 9.00m x 9.00m x 3.15m high in total.

Solution

Thicker ceiling panels (150mm versus 80mm for the walls) were required for the HEPA air filtration system. To maintain the hygienic specifications of the cleanroom, the panels have an easily cleanable laminated finish. Vision panels will ensure that production can be overseen from outside the cleanroom area. Our experienced installation team completed the build in just four and a half days.

Installer team were very good and end user was very happy.

David Pomeroy, Monmouth Scientific

Outside view of cleanroom suite for injection mouldings

Personnel hinged door for injection moulding cleanroom

Sliding access door for injection moulding cleanroom

Location	Ross on Wye
Building use	Injection Moulding
Panel Core	PIR
Panel Supplier	Kingspan
Panel Thickness	80mm, 150mm
Panel Facing	Laminated Food-Safe Finish 120 Micron Thick
Doors/Floor	Personnel Doors, Heavy Duty Sliding Chiller Doors
Panel Requirements	248.5m²
Other	Vision Panels

ADC Manufacturing Facility Fit-out

Merit Holdings

Background

Based on over 7 years of successful history in delivering high-value critical environment projects together, Merit Holdings selected CREST for the fit-out scope of their turnkey contract for a global pharma company’s UK ADC manufacturing facility in Scotland.

Process

Thanks to CREST’s expertise in such projects, we worked with the client and third parties since the early stages, attending their weekly design meetings to consult on the envelope specification and provide a detailed drawings within their Revit model.

CREST’s scope of works included the cleanroom envelope fit-out of two levels of a three-storey building, with multiple GMP Grade C & D cleanrooms and a large pharma cold store. Systems specified included Puracore and Kingspan Versatile.

Project delivery

Due to the complex nature of the project combined with large area covered by its scope, totalling 1750 m², CREST appointed a full-time site manager. With their proactive approach and vast experience running critical environment fit-outs, the team was able to predict challenges, act and implement changes instantly, allowing the client to hand over the building in a timely manner.

Outstanding work from our teams to ensure the variety of systems and details blended together seamlessly.

Bob Stevenson, CREST

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FM-approved Cleanroom Upgrade

Electronic Components Manufacturer

Background

Our client, a global manufacturer of electronic components for the automotive sector, contacted CREST with a need to upgrade their existing cleanroom facility on site in Bedford.

They sought after an architectural envelope contractor that could supply and install an FM-approved cleanroom system in order to comply with their latest insurance conditions.

Process

Following a site visit to understand the scope of the project in more detail, CREST proposed to undertake the removal of existing cleanroom walls followed by their replacement with the FM Approved Puracore system, including all doors and vision panels.

Given our client’s operational commitments, a 10-day shutdown of the main cleanroom was agreed, but most of the works on site had to be completed while it was still operational.

Project Delivery

Working within a live cleanroom environment required a stringent construction schedule and daily health & safety briefings to manage personnel moving in and around the works area.

This also meant that some areas of the existing cleanroom envelope couldn’t be assessed while the original site surveys were carried out, so CREST’s site and in-house design teams worked in real time to identify issues and update drawings.

The flexibility of Puracore’s cleanroom system combined with CREST’s experienced workforce allowed for on-site adaptations easily, which saw the build handed over within 12 weeks.

A real pleasure to assist our client with this cleanroom upgrade

Lee Duffield, CREST Construction Director

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Divisional Wall for a Medical Equipment Manufacturer

Intersurgical

Background

Intersurgical, a global manufacturer of devices for respiratory care, reached out to Stancold to commission a divisional wall to separate production and storage areas.

Our client’s Facilities Manager recommended composite panels to their leadership team, who had never used such materials before. The essential factor was the non-disruptive installation method and Stancold’s guarantee for the facility to remain partially operational.

Process

Having conducted a site visit, Stancold proposed a non-fire-rated solution based on Kingspan Quadcore panels. The team recommended a set of rapid-rise doors to further limit dust from spreading around the critical parts of the warehouse.

Stancold’s sales & estimating teams delivered a satisfactory quotation, but the client’s yearly budget planning forced them to delay the project. Thanks to our commitment, we heard back from the client a year later.

Project Delivery

The build was completed in ten days, serving as an exemplary introduction to composite-panel-based construction to the client’s leadership team. Impressed by Stancold’s flexibility, efficiency, and the quality of the installation they decided to switch to such solutions for future projects.

We are extremely impressed with Stancold. The focus the team gave the project and their adaptability were brilliant. They will be my company of choice in the future.

Richard Howse, Facilities Manager

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Medical Research Cold Storage

Cancer Treatment Research

Background

CREST were invited by the project’s main contractor to tender for the turnkey cold room package that formed part of a new cancer research and treatment centre in central Manchester. Spanning ten storeys, the vast building required cold storage facilities for drugs and biocultures across four levels.

Process

The package required the supply and installation of three dual-compartment stores and four separate chillers and freezers within the building, which included the envelope build, refrigeration, flooring and lighting. Freezer temperatures needed to be at -20°C and chiller temperatures at +4°C.

CREST’s team were pivotal in providing guidance and support on the room specifications to both the contractor and the architect throughout the contract negotiation process.

Project Delivery

Due to the size of the building and the different working locations for our team, loading procedures to get materials and plant to the necessary levels were complex. A small goods lift was available to be booked for use by contractors on site, so required thorough planning from our team to ensure our works schedule was not impacted by loading delays.

Used to the challenges of large-scale contracts, the team demonstrated flexibility as the construction programme frequently changed, while working systematically alongside other trades on site to co-ordinate installation activities.

It was a privilege to be involved in this transformational research facility

Mark Kendrick, CREST Business Development Director

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N+1 Laboratory Cold Store

Cravencroft

Background

CREST were approached by South-East engineering contractor, Cravencroft, for the turnkey supply and installation of a cold store, as part of wider refurbishment works for a biotechnology services provider.

Process

Located in the sample storage area of a laboratory, the +4°C cold store specified N+1 redundancy capabilities as part of its operation, so required an experienced contractor to confidently undertake all elements of this package.

Satisfied with the level of detail provided from CREST during tender stage, Cravencroft appointed the team as the turnkey cold storage contractor for this project.

Project Delivery

CREST’s dedicated installation team successfully supplied and installed a cold store with an N+1 refrigeration system that met +4°C temperature specification. This included an auto changeover function to initiate the backup system if necessary.

The room itself was to be housed within a number of other traditional build rooms, generating a tight co-ordination programme for CREST’s first fix refrigeration works. Once complete, other trades were scheduled to carry out their responsibilities before our installation team could continue their build package.

This was another successful pharmaceutical cold store contract for CREST, utilising key technical expertise for the safe storage of high-value sample materials.

CREST demonstrated exemplary co-ordination all throughout the project.

Lee Duffield, CREST Construction Director

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Turnkey Pharmaceutical Cold Stores

Overbury

Background

CREST were approached by leading fit-out company, Overbury, as a specialist pharma cold storage contractor for one of the world’s leading biopharmaceutical innovators.

A pharmaceutical cold room was required on each floor of the end user’s two-storey research & development site in Stevenage, and came as part of wider ongoing refurbishment and modernisation works.

Process

CREST’s expertise in turnkey cold store construction for high-value pharmaceutical products confirmed that we were able to provide vital N+1 redundancy solutions and select a sustainable refrigerant option in line with the project specification.

Our team worked closely with Overbury during negotiations to ensure that the specification and build programme were in line with the end user’s requirements.

Project Delivery

Both turnkey cold room packages were designed and built to maintain an internal temperature requirement of +4°C. The rooms themselves utilised a panel system with FR30 rating, as per the contract’s specification.

Working on the first and second floor of the building meant materials were maneouvred via an internal freight lift and external hoist, a challenge that the team are well-versed in navigating from previous site experience.

Aligning our start on site with a rescheduled programme of works required pro-active coordination to ensure that the project was completed in a timely manner and to the end user’s satisfaction.

A successful turnkey contract for high-value pharma products

Steve Gunning, CREST Contracts Supervisor

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ISO 7 Laboratory

Mildren Construction

Background

Following Stancold’s work with main contractor, Mildren Construction, for fire-rated and food-safe environments over the years, the group’s dedicated cleanroom entity, CREST, were invited to tender for the architectural cleanroom envelope construction of a temporary cleanroom in Southampton.

Process

The end user required a temporary cleanroom within their new warehouse space as a stop-gap solution for their future expansion.

The 180m² cleanroom had a requirement to meet ISO 7 standards, so CREST were able to specify a cleanroom envelope system best suited for this type of application.

The team continued to revise their proposal in line with design changes until the final order was agreed.

Project Delivery

The team utilised Kingspan’s Versatile system for the cleanroom envelope build, which included the integration of double leaf cleanroom doors and semi-flush vision panels to meet an ISO 7 standard.

CREST mobilised quickly to adhere to the proposed programme of works, co-ordinating our construction schedule in line with other trades working on site. Our dedicated team of envelope installers successfully completed the build in less than 2 weeks, leaving Mildren Construction and the end user satisfied with the works.

CREST were a pleasure to work with on this project and the service was seamless from initial pricing through to design and subsequently installation

Richard Holmes, Mildren Construction Director

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Biomedical Holding Freezers

Pharmaceutical Manufacturer

Background

CREST previously completed the envelope fit-out of six cleanroom suites on this pharmaceutical manufacturing site and thanks to unrivalled knowledge of turnkey cold storage construction within the industry, were subsequently appointed for this requirement too.

Process

Situated in a modular warehouse on the ground floor of the site, our client required two industrial freezers for additional product storage. The specification required product to enter the room at -20°C and be maintained at this temperature.

CREST undertook the turnkey package, which included refrigeration, lighting, shelving and access ramps.

Project Delivery

CREST successfully coordinated the room build, commissioning of refrigeration and installation of internal shelving in line with our client’s specification.

The scope also included removable access ramps, person trapped alarms and door release functions, with racking designed around evaporators to optimise airflow.

Utilising knowledge of the different elements required for a turnkey solution like this ensured a seamless programme of works through CREST as the appointed contractor.

CREST has unrivalled expertise in turnkey pharma cold storage

Steve Gunning, CREST Contracts Supervisor

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GMP Grade C & D Cleanroom Envelope Modules

Merit Holdings

Background

CREST were pleased to work with off-site construction specialist and long-standing client, Merit, to deliver 14 no. EU GMP Grade C & D cleanroom modules for a new state-of-the-art pharmaceutical innovation facility.

Process

Through a combination of traditional and modular construction practices, CREST were required to fit out the cleanroom modules off-site before they were transported to the facility in Darlington and integrated over two floors. Our expert team developed an architectural envelope specification that not only met the cleanrooms’ GMP conditions, but also took into account the intricacies with the logistics of the project.

Project Delivery

CREST’s dedicated installers utilised the Puracore cleanroom system, complete with flush doors, flush vision panels and a PET finish that could withstand the use of vapourised hydrogen peroxide (VHP) within its cleaning regime.

Once the modules were in situ, a final visit to the Darlington facility allowed our team to quality-check and cover finer details within the build.

The team worked tirelessly to ensure that the design and material lead-in were co-ordinated to the build programme, achieving a turnaround time of 14 weeks.

CREST showed flexibility through such an intricate project.

Lee Duffield, CREST Contracts Director

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Fire-Rated Cleanrooms

Rydon Construction

Background

Following previous experience with the contractor, CREST were invited to tender with Rydon Construction for the fire-rated cleanroom fit-out of a new purpose-built aerospace centre in Bristol.

Process

Our team were involved from the early stages of this project to assist with the technical specification that included both passive fire protection and ISO standard cleanrooms.

Negotiations and design meetings were conducted virtually due to COVID-19, before site surveys followed once the green light was given for the project.

Project Delivery

CREST installed composite walls, ceilings, doors and vision panels to form a number of areas as part of the fit-out. This included production and preparation zones and accompanying airlocks.

The project utilised Eurobond’s Firemaster system with a white food-safe coating throughout, which achieved both a FR30 rating and a cleanroom finish to meet the specification requirements. System doors were also included to ensure no necessary additional secondary steelwork was needed.

Working alongside other contractors within an open warehouse required methodical planning and co-ordination by the team and was managed well to ensure that our build schedule was uncompromised.

You managed issues with delay (by others) well

Neil Spurway, Rydon Construction

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Fire-rated cleanrooms for aerospace Bristol

FR30 and cleanroom finish across the facility

Chilled & Ambient Pharmaceutical Storage

Pharmaceutical Distribution

Background

CREST were approached by our client to deliver temperature-controlled pharmaceutical storage within their existing warehouse. Our team were able to offer a turnkey package and assumed responsibility for the panelling, refrigeration, lighting, doors and door protection.

These environments were to be utilised for the storage of temperature-critical pharmaceutical products and aid our client’s compliance for good distribution practice (GDP).

Process

Understanding the bespoke nature of critical environment builds such as this, the team completed multiple site surveys to gain a better understanding of the site conditions and to confirm minor design changes.

Project Delivery

Our specialist installation team successfully supplied and installed the pharmaceutical chiller, meeting the 2-8°C temperature specification, with adjoining ambient area (15-25°C), and utilised Kingspan’s QuadCore panel system to do so effectively. Situated underneath a mezzanine floor, the team had to carefully plan the coordination of refrigeration and HVAC equipment to accommodate.

Whilst there was good access to the site, it remained a live environment, so daily coordination meetings were arranged to minimise disruption to day-to-day operations.

However, the team are well-versed in overcoming such intricacies and worked hard to successfully deliver the project according to our client’s programme of works.

A build that demonstrates our pharma expertise

Lee Duffield, Contracts Manager

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Pharmaceutical distribution chiller build

Cleanroom Extension Fit-Out With Firewalls

Pharmaceutical Manufacturer

Background

Working under on-site project management contractor, Specific Environments Ltd, who were responsible for developing a full turnkey cleanroom solution, the Stancold’s Clean Room Envelope Specialist Team were tasked in undertaking the cleanroom envelope fit-out within this pharmaceutical manufacturer’s new extension.

Process

The project required an intricate scope of works to best accommodate the end user’s accelerated manufacturing plans and utilisation of redundant space, in and around complex steel structures.

Our team’s consultative nature allowed us to explore a number of panel system combinations with the end user, taking into account the need for fire protection and their budget.

The final package required the integration of three different panel systems to ensure that the specification was successfully achieved.

Project Delivery

Stancold’s responsibilities included the construction of all cleanroom walls, walk-on ceilings, doors, vision panels and 60-minute firewalls, amounting to nearly 8000m² of works.

The team combined Puracore’s Aluminium Honeycomb, Kingspan Versatile and Eurobond Firemaster panel systems to complete the works, utilising each system’s advantages to match the overall complexity. A key strength within our offering includes the ability to accurately colour match all systems, which provided a perfectly white finish throughout this facility.

Two installation teams worked in unison to complete the construction of the cleanrooms and firewalls simultaneously, so the project was successfully finished within the assigned schedule of 15 weeks.

A complex build that exhibits our specialist knowledge

Lee Duffield, Senior Contracts Manager

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Temperature-Controlled Biopharmaceutical Production Facilities

Area

Background

Commercial workplace specialists, Area, part of the wider Fourfront Group, required a contractor to undertake the design and build of four temperature-controlled facilities within a newly built warehouse in Hampshire.

The warehouse’s new tenant manufactures key machinery systems for the life sciences and biopharmaceutical sectors, and this area will house the final testing phase of their production line.

Process

CREST worked closely with Area’s team and our recommended refrigeration partner to find a system that would accommodate the required temperature range of +2°C to +26°C.

Where the facility operates a large robotic crane, CREST also carefully considered different door options and proposed a suitable solution as part of our package.

Project Delivery

CREST delivered four chilled rooms and accompanying doors to facilitate this project’s specification. Kingspan’s Quadcore panel system was the best suited option for this application, thanks to its reliable insulating properties, and space-saving roller-shutter doors integrated within the design to accommodate the warehouse’s crane.

Two areas were built beneath an 8m-high mezzanine floor, so the team created an efficient workaround plan to install ceilings safely, where access was particularly tight. Manoeuvrability of wall panels and use of lifting equipment in this space were also carefully monitored, especially when coupled with other craning machinery within the main warehouse.

CREST successfully completed the works within 3 weeks, demonstrating strong expertise and faultless construction technique for this application.

Our team successfully achieved the intricate specification

Sam Glover, Senior Contracts Manager

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Industrial Battery Manufacturing Centre – Internal Fit-Out

Merit Holdings

Background

Coventry’s UK Battery Industrialisation Centre (UKBIC) is a new state-of-the-art facility to support the research, development and evolution of high-volume manufacturing of advanced battery technology. For use initially within electric vehicle production before scaling more widely, this Government-funded space will help support the UK’s move to become a low carbon economy.

Due to Stancold’s technical expertise and innovative approach, we were engaged by Merit Holdings in the early stages to develop and assist the design.

Process

As a multi-discipline contractor of over 70 years, our knowledge of temperature and humidity-controlled environments, thorough understanding of passive fire construction and exclusive cleanroom technical strengths enabled us to work tirelessly and collaboratively with suppliers and the client’s projects team to ensure a robust ‘right-first-time’ solution to meet the onerous specification:

• ISO 8 cleanroom condition
• -73°C dew point supply & -60°C dew point return
• Temperature 21 +/-2°C
• Ambient air humidity as low as 0.5%
• 60-minute fire-rating
• Static dissipative

Solution

Stancold’s exclusive cleanroom installation team completed the construction of 31 assembly rooms including:

• Anode and cathode mixing facilities
• Anode and cathode calendering areas
• Material airlocks, personnel airlocks and changing rooms
• Pouch assembly and filling
• Linking corridors

This accommodated two main production lines running parallel throughout the building, complete with ageing ovens for the final stage.

A mix of insulated and fire-rated products were used, along with specialist detailing to ensure that the installation passed the rigorous commissioning and testing procedures, vital for such a sensitive manufacturing process. ‘Free-spanning’ panels in excess of 9m were integrated into the design by Stancold, thus eliminating the need for tonnes of secondary steel, whilst still ensuring the fire rating was achieved.

All panel systems and ancillaries were meticulously colour-matched and complete with a 120-micron PVC laminate finish for a seamless integration and maintenance of cleanliness throughout. Openings were carefully created to allow machinery to pass through each area and neighbouring link corridor.

With a build time of 10 months, our team worked tirelessly from project conception to the final handover to develop, supply and install an envelope that would meet the complex specification required for this new generation of high-end and high-volume manufacturing.

Stancold went above and beyond in demonstrating our capabilities

Lee Duffield, Senior Contracts Manager

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Complex specification for industrial battery manufacturing centre fit-out

ISO 7 Cleanroom For Medical Device Manufacture, Leeds

Medical Device Supplier

Background

Stancold’s successful relationship with turnkey cleanroom contractor, Monmouth Scientific, allowed us to work together once more to undertake a project with a medical device supplier in Leeds.

Process

Our team put together initial budget costs for the works, which were then confirmed with a full site survey. This visit allowed Stancold’s allocated project manager to assess any spatial restrictions and key access points for installation.

Based on a busy industrial estate, an out-of-hours delivery schedule was put in place to manage loads coming into the area and ensure minimal disruption to neighbouring businesses and ultimately, our scheme of works.

Solution

Our specialist installation team delivered a cleanroom that met ISO 7 standards, along with an air lock changing area, that achieved an ISO 8 specification.

Kingspan’s Versatile cleanroom panel system was best suited for this standard of controlled environment, where taller panels were installed along the front of the facility to hide HVAC equipment on the ceiling. The team were able to adapt the panel system to form air return ducts as part of the required design.

Semi-flush doors were also installed, complete with interlocking.

Stancold’s expert product knowledge and comprehensive planning process ensured the successful delivery of this project.

Stancold demonstrated flexibility and expert product knowledge

Paul Towse, Stancold Project Manager

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ISO 8 Cleanroom for Electrical Components Manufacturing, Dundee

Electrical Manufacturing

Background

Stancold worked with cleanroom contractor, Monmouth Scientific, in Dundee to successfully construct a new cleanroom for an electrical components manufacturer.

Process

Stancold’s strong expertise in the design and build of the cleanroom envelope were fully utilised throughout this project, where three different panel systems were integrated to create a new ISO 8 cleanroom and glazed office partitioning.

Our team were able to offer valuable advice on each system and discuss how it would work within the finished facility, all confirmed with a site survey to visualise the agreed design and understand site conditions.

Solution

The project encompasses approximately 523m² of insulated panelling, with the ISO 8 cleanroom constructed using the semi-flush Kingspan Versatile system, of 100mm thickness.

The accompanying office space utilises a Puracore glazed wall system, which includes 50mm Aluminium Honeycomb panels with frosted double-glazed flush windows and a fully glazed door. All ceilings across the two areas employ the Kingspan Versatile system. Mineral Fibre panelling was also installed as part of this project’s specification.

Our installation team’s panel construction expertise was fully exercised throughout, as the build was carried out while the facility remained operational, thus not impacting on the end user’s production capabilities.

Utilising three panel systems demonstrated the team's excellent construction experience

Lee Duffield, Project Manager

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Inside the ISO 8 cleanroom for electrical component manufacture

Cleanroom for electrical component manufacture

Hygienic Production Areas for Essential PPE Manufacturer, Leicestershire

Pal International

Background

Manufacturer of cleaning & PPE products, Pal International, approached Stancold in the midst of the COVID-19 pandemic. Due to the Government advice imposed across the UK, they saw their product range in significant demand. To facilitate this sudden increase, they required additional space to house a new production line.

Process

Stancold reacted quickly across every aspect of this project. To ensure the client made effective use of their vacant space, we undertook a consultative approach and value-engineered a design that utilised existing walls.

Where the project needed to be on site within a matter of weeks, our long-standing relationships with manufacturers and suppliers were vital in ensuring a rapid turnaround to begin construction.

Solution

The project’s final design involved 6 new hygienic areas, all at differing heights, with openings to accommodate product equipment, alongside the installation of personnel doors.

Kingspan’s Quadcore panel system was best suited for this build, due to its high-quality hygienic finish. Ongoing circumstances meant that health & safety was a key consideration while working on site, where the team adhered to strict social distancing measures and precautionary checks as advised by Pal International.

Stancold’s ability to mobilise quickly and work efficiently during such unprecedented times ensures that our client’s tight schedule was met and their operations unaffected.

Demonstrating efficiency and safety were key in this project.

Sam Glover, Stancold Contracts Manager

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Hygienic Rooms Built For New Production Lines

ISO 8 & 9 Cleanroom Areas for Aerostructures Manufacturing, Scotland

Aerostructures Manufacturing

Background

Working with Specific Environments, our end user required ISO standard 8 and 9 areas as part of a new aerostructures research and development complex within a large hangar in West Scotland.

Process

A site survey determined all design and construction details for the project, allowing our CAD team to expertly create accurate drawings, gaining approval from the client and preparing the Stancold team for the build.

Co-ordination of materials, plant and ancillaries was a key factor of the planning process, given its rural Scottish location and 400-mile distance from Stancold’s Head Office.

Solution

Stancold completed the install using Kingspan Versatile Quadcore panels, a composite system designed for semi-flush cleanroom environments such as this.

The team were responsible for all 50mm and 80mm hygienic panelling, spanning over 1500m², and the 100mm walk-on ceiling, to be used for maintenance access. Rapid-rise doors, personnel doors and single-glazed vision panels completed the build.

The team worked really hard to construct within and around the existing steelwork on site, alongside other contractors, to complete the project to our client’s programme of works.

A successful cleanroom build for an exciting project

Lee Duffield, Stancold Project Manager

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Freestanding Puracore Internal Partitioning, Plymouth

Medical Technology

Background

After successfully completing previous work on site, Stancold were recommended by the end user to undertake this project. This involved collaborating with a specialist main contractor for the first time to construct a number of freestanding flush partitions, used to separate machinery and work areas.

Process

The Puracore cleanroom system has already been utilised as part of our previous installation, so the end user was satisfied for the high specification composite panels to be used again.

A full site survey was undertaken by the projects team, to meet with the contractor and understand the full scope of works required.

Solution

Stancold were responsible for the supply and install of a number of freestanding flush partitions, complete with half-height glazing.

Utilising the Puracore Aluminium Honeycomb system and accompanying flush vision panels throughout, Stancold were able to demonstrate our unrivalled technical and installation knowledge once again to successfully complete the works.

The team incorporated white painted 50mm x 50mm box steel section posts in order to support the walls yet still achieve a flush wall panel finish.

The project was completed in one week on site, to both the contractor’s and end user’s satisfaction.

Showcasing our Puracore expertise

Paul Towse, Project Manager

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GMP Manufacturing Cleanroom Suite, Stevenage

Pharmaceutical Manufacturing

Background

Stancold have built a strong relationship with this project’s successful main contractor thanks to previous experience together and were selected to complete the cleanroom works as part of this expansion project in Stevenage.

Process

As the project’s design evolved, Stancold worked tirelessly to revise quotations to suit, meeting with the contractor to see the site’s existing cleanrooms and expansion area. This was also where our design and projects teams later clarified construction details, panel layouts and programme to ensure a smooth start to the installation.

Where the new suite will undergo tough cleaning regimes when fully operational, it was key that the products used for the build would be able to withstand such levels. Stancold were pro-active in submitting all technical information for the end user’s approval.

Solution

The manufacturing suite utilises the fully flush FM Approved Puracore cleanroom system in order to achieve the desired Grade C & Grade D standard throughout.

Fully flush vision panels with 6mm toughened glass are incorporated within the Aluminium Honeycomb partitioning while all service points are neatly integrated.

Over 100 fully flush single and double personnel doors have been installed, complete with a motion-sensor interlocking network from main corridors to airlock spaces through to cleanrooms, preventing contamination. A walk-on ceiling with a hidden suspension system allows for maintenance access where required, while bump rails within the clean-not-classified corridors and material airlocks add protection to outer cleanroom walls.

Our experienced installation team completed this project in 6 months, where our dedicated workmanship and attention-to-detail demonstrated Stancold’s unrivalled Puracore expertise, from design through to final handover.

Stancold's scope of Puracore cleanroom installation excelled in this project

Lee Duffield, Stancold Project Manager

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Low Humidity Cleanroom For Battery Production, Romsey

Battery Technology

Background

Stancold recently travelled to Romsey to install a fully flush cleanroom system for a specialist in solid-state battery production.

Process

Our extensive knowledge of different cleanroom systems on the market allowed us to suggest what would be best suited to this project and then adapt based on the user’s specific requirements.

Once confirmed, our projects team commenced with site surveys, construction drawings and door schedules in preparation for the start date.

Solution

Stancold utilised the Kingspan Precision cleanroom system; a framed, flush system where panels were made to size, alongside the expert installation of flush vision panels, a full-height glazed wall and flush hinged personnel doors.

Chiller doors were also selected and integrated into the build of the main cleanroom areas, as they demonstrated the most appropriate sealing properties to establish a very low humidity level that is required when working with lithium.

Being able to adequately meet the various requirements of this project, from humidity levels to a fully flush system, was due to the team’s experience and knowledge in working with market-leading materials, therefore creating a bespoke facility that met our client’s needs.

Our superior knowledge of the cleanroom market was valuable

Lee Duffield, Project Manager

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Advanced Research Laboratory, University of Sheffield

University of Sheffield

Background

Following a glowing reference from a cleanroom project on an alternative site, Stancold were recommended for these works with the University of Sheffield.

Process

The Advanced Manufacturing Research Centre (AMRC) were continuing to expand their operations within their powder manufacturing and processing facility.

Utilising our strong industry experience, Stancold developed the concept and produced a design proposal for the works, which was then finalised through a site survey with the project management team.

Solution

Our team were responsible for installing Kingspan Quadcore panels of 80mm thickness and a walk-on ceiling of 100mm to form the laboratory. Alongside this, the integration of hinged personnel doors and vision panels were completed.

Stancold also undertook the installation of the accompanying air conditioning and humidity control functions, so that the facility was able to maintain a consistent 20°C. This was crucial for the activities taking place within the lab.

This project was successfully completed in four weeks and Stancold left site with a satisfied end user.

Successfully developing the lab's concept and design was due to strong industry experience.

Lee Duffield, Project Manager

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4,000m² Fill Finish Cleanroom Facility For Vaccine Production, Liverpool

Boulting Environmental Services

Background

After working together previously, respected specialist cleanroom contractor, Boulting Environmental Services, invited Stancold to tender for the installation of 4000m² of cleanroom panels in their latest pharmaceuticals project.

Process

This project required Stancold’s expertise and experience within pharmaceutical cleanrooms to install Aluminium Honeycomb and insulated panels, forming a new Fill Finish facility. The end user, a worldwide manufacturer and supplier of vaccines, were moving this area of operations in-house to their manufacturing site in Liverpool.

Solution

Stancold installed both Kingspan QuadCore and Puracore Aluminium Honeycomb panels to successfully complete the fit-out. Covering two floors of the facility, the cleanrooms were constructed simultaneously by two separate Stancold teams, achieving a semi-flush environment within the lower level and a fully flush, high-end pharmaceutical cleanroom on the upper level. The build also included the integration of flush single hinged, double hinged and personnel doors, as well as double glazed flush vision panels. Three cold storage units were also required as part of our installation package.

Stancold’s strong technical ability in installing controlled environments was fully utilised throughout this 20-week project on site.

With a difficult design to follow and a tight programme, it was an excellent install.

Steve Daly, Boulting Environmental Services

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Pharmaceutical Cold Storage, Liverpool

Boulting Environmental Services

Background

After working together previously, respected specialist cleanroom contractor, Boulting Environmental Services, invited Stancold to tender for the cold storage works in their latest pharmaceuticals project.

Process

Alongside over 4000m² of composite cleanroom panels, the large project required Stancold’s expertise and experience to integrate three pharmaceutical cold stores, including refrigeration, within the new Fill Finish facility. The end user, a worldwide manufacturer and supplier of vaccines, required facilities to house their products and materials under controlled temperature conditions.

Solution

Stancold installed Kingspan panels of 100mm thickness to create the three cold stores measuring 18.5m x 7.8m, 10m x 3.7m and 10.3m x 6.5m, and were integrated with insulated rapid roller doors, fire escape doors and insulated sliding doors for efficient product and personnel access. Two cold stores on the ground floor required a ‘controlled not classified’ status while the third, located on the first floor, needed to achieve EU GMP Grade D standard. The units have been constructed to achieve a temperature range of +2°C to +8°C in order to meet the requirements of the product.

Like in many pharmaceutical cleanrooms where the value of the product being stored is so high, all cold stores required 100% backup, so if any equipment fails, the rooms will still remain fully operational.

This project demonstrated Stancold’s full capabilities in installing pharmaceutical cold storage for vaccinations, using our extensive technical knowledge to meet the needs of our clients.

With a difficult design to follow, it was an excellent install.

Steve Daly, Boulting Environmental Services

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Fully Flush ISO 8 Cleanroom Suite For Probiotics Production, Somerset

NGS Cleanrooms

Background

Stancold have a long-standing relationship with cleanroom specialists, NGS Cleanrooms, who undertook the design and construction of an ISO 8 cleanroom suite for their client, a probiotics manufacturer in Somerset.

Process

Stancold worked closely with NGS Cleanrooms and Puracore, producing detailed design plans for the large bespoke cleanroom build.

Solution

The project required the installation of 1250m² of FM Approved Puracore Aluminium Honeycomb Cored panels, fully flush vision panels and rapid roller shutter doors to form 28 processing rooms. Stancold also supplied and installed an integrated one-hour firewall, using Kingspan Mineral Fibre Cored 100mm panels. This included the fitting of double ‘hold open’ fire-rated personnel doors and all firestopping to achieve maximum fire integrity. Stancold were responsible for the suite’s cold storage facility, constructed using Kingspan Quadcore panels and completed with a white food-safe finish to match the rest of the Grade D cleanroom suite. There were a number of intricate and complex details to the project, such as the seamless integration of motion-sensor service points for doors and air return columns. Stancold’s specialist expertise and strong cleanroom experience enabled the 6-week bespoke project to be completed successfully.

Stancold's expertise in this field really shone on this project.

Lee Duffield, Stancold Project Manager

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Cleanroom installation for pharmaceuticals

Fully flush vision panels for cleanrooms

Fire-Rated Cleanroom Partitions for Modular Building, Coventry

Catfoss Group Manufacturing

Background

As part of an ongoing expansion for an R&D manufacturing campus, Catfoss Group Manufacturing were constructing a modular building and required a number of clean fire-rated areas.

Process

As an offsite modular construction, site surveys could only be completed once everything was in place on site, where Stancold then worked efficiently to complete the necessary surveying and design tasks prior to installation.

Solution

Working to a tight programme of works, Stancold supplied and installed approximately 250m² of fire-rated partitions, 80mm thick Kingspan Mineral Fibre Cored panels were used to create several clean areas with a corridor.

The team also installed 8 no. 60 minute fire-rated double hinged personnel doors, which were compliant to DDA standards. This was in conjunction with firestopping products to the partitions to ensure a fire-rating of up to two hours throughout.

Stancold worked well, especially in the conditions you were working in

Andrew Noble, Catfoss Group Manufacturing

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Warehouse fire-rated clean partitions, Coventry

Fire-rated clean partitions for warehouse

Cleanroom Partitions For Medical Technology Provider, Devon

Haldons Construction

Background

After successfully working with Haldons Construction Consultants at a medical technology company in 2017, Stancold were asked to complete a second cleanroom partitioning project on the same site.

Process

As this was a complex project and was to be conducted in a live environment, the Stancold team attended numerous site visits with Haldons and the end client to discuss finer details of the installation process. Working closely with both parties provided the necessary support in the pre-construction stage of the project.

Solution

As per the client’s requirements, Stancold dismantled and removed the temporary walls in place and then erected 500m² of new cleanroom partitions using Kingspan Quadcore 80mm panels integrating a hinged personnel access door.

Using our strong expertise of working in a live environment, appropriate measures were implemented to ensure no construction debris left the area outside of the temporary screens and panels were cut away from the construction area, allowing the client’s working operations to continue as normal.

Communication from Stancold is always brilliant

Simon Buchanan, Haldons Construction

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Cleanroom partitions with hinged personnel door

Cleanroom 80mm partitioning on site at medical device manufacturers

Cleanroom partitions for medical device manufacturers

Cleanroom Suite & Firewall Partitions for Aeronautical Research & Development

Precision Manufacturer

Background

Using our unique experience of cleanroom design and construction and fire-rated enclosures, Stancold were awarded the project after winning a competitive tender through Principle Contractor, Merit Holdings.

Process

The suite of new cleanrooms was built to grade D classification and the fire-rated enclosures were designed to be clean not classified.

Solution

We installed 6m high freestanding walls with integrated flush cleanroom windows connected to an aluminium T-Bar suspended ceiling grid which formed the plenum and low-level return air cooling coils. The return air ducts were formed using 50mm FM approved Puracore cleanroom walls to a height of 6m and we also provided temperature controlled cleanrooms with Eurobond panels to a height of 8m.

This project showcases our cleanroom expertise

Paul Towse, Project Manager

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Puracore honeycomb panels for aeronautical research cleanroom

Aeronautical cleanroom facility installed by Stancold

Cleanroom installation including flush cleanroom windows

Cleanroom panels in viewing gallery for aeronautical research

ISO 6 Cleanroom for Precision Engineering Manufacturer

Specialist Manufacturer

Background

With their business expanding, this manufacturer was looking to build a new multi-room cleanroom. Our technical expertise means we partner regularly with Monmouth Scientific on cleanroom projects.

Approach

This project required a cleanroom environment for a precision engineering manufacturer. We offered a cost-effective solution that ensured all requirements for a controlled environment were met.

Solution

The cleanroom measures 18.00m x 4.35m x 2.825m high and is split into 4 different rooms. There are 14 (1220mm x 610mm) ceiling openings for HEPA filters and 8 vision panels. The main compartment is ISO 6 standard.

To ensure that the air in this space meets those specifications, Stancold installed two airlock rooms that are controlled with maglock door system.

Another high spec cleanroom that meets ISO6 Standards

Lee Duffield, Stancold

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Installing a multi-room cleanroom for a precision engineering manufacturer

Cutting panels for a cleanroom installation

Cleanroom ceiling with openings for HVAC filter system

Triple Compartment Cleanroom, Preston

BSRIA

Background

BSRIA are a test, instruments, research and consultancy organisation who were opening an office in Preston and needed a cleanroom for the new site.

Requirement

A triple compartment cleanroom, comprising of a temperature lab, pressure lab and blower door rig. Stancold installed four hinged clamp frame personnel doors, one hinged emergency exit door and a heavy duty sliding chiller door as well as seven single pane vision panels.

Solution

Installed in the existing building, the new cleanroom was to be used for accredited product testing. Each room allows for different forms of testing in a controlled, hygienic environment. The heavy-duty sliding chiller door allows easy access for large pieces of equipment and the vision panels enable people to observe the testing from outside the cleanroom environment.

We were all hugely impressed with the job, everything was done very well. If we ever have need of such work again I would definitely use you.

June Davis, BSRIA

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Sliding door access for triple compartment cleanroom

Compartment cleanroom with vision panel and personnel door

The build continues of a triple compartment cleanroom

Building a triple compartment cleanroom in Preston

Pharmaceutical Temperature Controlled Storage

Dribuild

Background

Based just outside London, in Ashford, the transport and logistics company, GEFCO Forwarding, were expanding due to business growth and needed a new chiller and office.

Requirement

The chiller will be used by their customers to store pharmaceuticals. The temperature controlled room will sit inside the building. Measuring 14m x 15m x 7m, the interior was fitted out with high racking for storing of the pharmaceuticals, to ensure maximum capacity.

Solution

Stancold worked closely with Dribuild to ensure that the design of the chiller, which required 125mm panels for the ceiling rather than the usual 80mm, allowed for all of the services to go across the top of the chiller. A rapid rise door was installed for easy access.

We were happy with Stancold's quick response to changes and providing information that was requested. Stancold kept Dribuild up-to-date throughout the project with regards to lead times etc.

Joe Black, Dribuild

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Panels installed for pharamceutical storage facility

During the cold storage installation process

Fire rated and hygienic panels for pharmaceutical storage

Clean Partitioning for Pharmaceutical Distribution

Envoplan

Background

Family-owned business, Sigma Pharmaceuticals, grew into one of the largest pharmaceutical distribution services in the country and thus, expanded their operations into a new distribution warehouse in Greater London. Working with the project’s fit-out contractor, Envoplan, CREST were appointed to complete the internal fit-out of the space.

Process

Due to the nature of the pharmaceutical products being stored in the facility, the end user required a clean environment throughout, with considerations made to the U-value and a 1-hour fire-rating of the partition walls between offices and main warehouse.

Project Delivery

Working closely with Envoplan, CREST developed an internal fit-out design that accommodated the building’s existing structure, including the roof and external fittings.

To prevent damage to the partitions once forklifts and machinery were in operation, aluminium tread-plate protection was installed to a height of 1.25 metres.

Thank you for your efforts, well executed and looking very professional.

Greg Howarth-Hough, Envoplan

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Hygienic panels for pharmaceutical distributor in Watford

Hygienic environment for pharmaceutical distributor

Internal panel fit-out with tread plate protection

Bio Storage Chambers

Laboratory Services Provider

Background

Our customer is a trusted provider of first-class bio storage chambers, services and laboratory testing for global healthcare and pharmaceutical companies.

Requirement

To install four stainless steel bio storage chambers. Each chamber has the dimensions of 3.16m x 2.56m x 2.86m high with two doors, suitable for temperature-controlled bio storage for the preservation of test samples and pharmaceutical substances.

Solution

Stancold installed these high quality insulated bio storage chambers using thermally efficient PIR walls and ceiling panels coated with hygienic stainless steel, preventing bacteria growth and ensuring that joints are tight with no dirt traps for easy wash-down and maintenance.

You are our no 1 contracted supplier for environmental chambers.

Director of Manufacturing

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Semi-Flush Cleanroom

Snazaroo

Background

Due to continuous growth in product ranges and increase of global demand, our customer required a semi-flush cleanroom for the mixing of fine powder pigments and cosmetic ingredients to produce their 100% skin friendly paraben and fragrance-free paints.

Requirement

Our scope of works consisted of a semi-flush ISO 8 cleanroom installation accommodating machinery and air vents, complete with a built-in atrium functioning as a high care changing area.

Solution

Stancold engineered a solution with a cleanroom panel system suitable for the application and achieving considerable savings for the customer.

Stancold specified a panel system capable of supporting 4 apertures for filters, supplied 3 vision panels, 3 transparent swing doors for better light conditions and security reasons.

You are very professional. We are very pleased with the installation and would recommend you to anyone.

Adrian Ryan, Snazaroo

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ISO 7 Cleanroom

Monmouth Scientific

Background

Our client was contacted by a leading manufacturer of conductor and fibre optic cables for the aerospace and defence industries who had the requirement for a new ISO 7 cleanroom.

Process

A 90m² footprint self-supporting cleanroom, complete with an airlock compartment, was required. Our client also required the design to perform with multiple ceiling openings to accommodate the lighting and HEPA filters, all built to a tight deadline and in a working laboratory environment.

Solution

Stancold provided Kingspan insulated wall and ceiling panels, expertly fitted with doors and windows and designed to take the ceiling loads. The project required close project management due to the restrictive programme and site conditions; access was tight and limited. Our experienced team once again rose to the challenge leading to another satisfied client.

Watch the project’s timelapse video here.

Excellent, a job really well done.

Dave Court, Monmouth Scientific

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ISO 7 cleanroom with insulated wall and ceiling panels

ISO 7 cleanroom with insulated wall panels

Research Laboratories

Johnson Matthey

Background

Johnson Matthey are a leading international chemicals and precious metals company headquartered in London.

Requirement

Stancold were contracted to build 2 research laboratories the area of 72m² and 36m², ladder enclosure and suspended ceiling in a high security environment.

Solution

In the absence of a structural beam, Stancold have created a specialist galvanised angle to suspend the ceiling from. The walk-on ceiling has provided the customer with easy access to their pipework ring main, thus reducing potential downtime in production areas. The ladder enclosure has provided excellent dust control which is of particular importance due to the product inspection requirements.

I will certainly recommend you and your installation team.

Mark Wall, Johnson Matthey

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Environmental Rooms

Bioscience Company

Company

This international bioscience company are widely acknowledged as leaders in the field of controlled environmental rooms and chambers, stability storage equipment and services in the pharmaceutical industry.

Application

To install 7 Chambers at the company’s facility in California, USA using high specification Puracore cleanroom panels. To delegate Stancold installation team overseas and coordinate the project from start to end.

We see Stancold as a partner and integral to our future business.

Manufacturing Director

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