AlbuRx Manufacturing Facility Expansion

Irwinconsult, a WSP company, provided engineering consultancy services for the design and construction management of CSL Behring’s new $210 million AlbuRx Manufacturing Facility in Broadmeadows, Australia.


Location

  • Victoria, Australia

Sector

Service

  • Mechanical, Electrical and HVAC
  • Hydraulic and Hydrological Modelling
  • Fire Engineering
  • (View all)

Client

  • CSL Behring Australia

Project Value

  • AU$210 M

Project Status

  • Completed in 2018

Architect

  • A5 Architects


CSL Behring, a member of the CSL Group of companies and a leading global biotechnology company manufacturing plasma-based and recombinant therapeutic products, awarded Irwinconsult a contract to provide engineering services for the design and construction management of a new AU$210 million advanced manufacturing facility to increase its global production of albumin. Situated at its Broadmeadows site in Victoria, Australia the new facility would provide an additional manufacturing capacity of 200 tonnes annually to meet worldwide demand for this critical care product, and complement existing manufacturing facilities in Bern, Switzerland and Kankakee, Illinois, USA.

 

Following on from our successful delivery of its Turner Privigen® Facility, this project would encompass the delivery of a new three-story facility built over two phases for the commercial manufacture of AlbuRx®, a blood plasma-derived intravenous critical care therapy used to restore blood volume in patients in the treatment of severe burns, shock, pancreatitis, postoperative albumin loss, hypoproteinemia, liver failure, and more.

 

Irwinconsult provided mechanical, hydraulics, fire protection and vertical transportation design services.

 

Solutions

A highly responsive and experienced project team allowed for quick responses and tailored design and documentation solutions to suit CSL’s site-specific needs.
Our flexible and adaptive design team was able to effectively change the design during the construction phase to accommodate significant client-driven design changes in a time and cost effective manner.

 

The AlbuRx facility included the design of process chilled water and cooling water plant, plant steam systems, air handling systems to serve Grade C cleanrooms and integration with pharmaceutical process systems by GEA, Germany. A microbiology laboratory area and PC2 sterility laboratory suite is also located within the facility.

Results

The project was fully documented in 3D Revit and consolidated with the 3D models prepared by A5 Architects and all other consultants to deliver a highly coordinated and clash-free solution. As a result, the construction coordination process occurred smoothly with minimal on-site modification.

 

As a prime example on how to bridge the gap between design, fabrication and construction, the 3D model produced during this project earned industry recognition at the Construction Innovation 2017 Forum. Jason Pleaner, Associates Director – Mechanical at our East Melbourne office in Australia, discusses the topic and project during a Forum workshop titled Design, Fabrication and Construct with BIM-MEPAUS.

 

This project represents a milestone on our continually growing relationship with CSL Behring Australia, which has also seen us deliver the new CSL Administration Building at Parkville, Main Store Expansion project and the Turner Privigen facility to name a few.

 

The Broadmeadows site  is home to Australia’s only plasma manufacturing facility and the only commercial scale facility of its type in the Southern Hemisphere.