Cleanroom Installation for a Global Animal Health Client

Introduction
Ardmac, a renowned specialist in constructing controlled environments, has successfully completed a full cleanroom installation for a leading global animal health company. This project, undertaken at their facility in Tullamore, Ireland, signifies a pivotal expansion as the client seeks to enhance their operations within the animal health sector. The installation commenced in August 2022 and was meticulously completed in July 2023, encompassing an extensive area of 2,800 square meters.

Project Overview
Scope of Work
The project’s scope included a comprehensive cleanroom installation, downflow booths, and auxiliary structures, specifically tailored for the animal health industry. Essential elements of the installation comprised:

• High-performance load bearing ceilings and cleanroom partitions
• Specialised doors, including rapid roller doors with automated functionalities
• Durable epoxy flooring
• Iris valves and terminal HEPA housings
• Low-level return systems integrated with ducting to ceiling level
• Door interlocking
• Stainless steel walls and floor protection systems

Additionally, Ardmac conducted critical commissioning activities, which included detailed checks on door functionalities, HEPA filter performance, lux level assessments, and rigorous room leakage tests to ensure compliance with industry standards.

Early Contractor Engagement: Maximising Efficiency through Design Collaboration

A crucial element that significantly enhanced the successful execution of the project was Ardmac’s proactive approach to early contractor engagement. By involving contractors at the initial stages of the design process, Ardmac fostered a collaborative environment that streamlined decision-making and planning. This forward-thinking strategy ensured that all stakeholders were aligned on design intent and construction requirements from the outset.

Through early engagement, Ardmac was able to identify potential challenges and solutions during the design phase which allowed the Ardmac team to execute their work efficiently, minimising delays and rework while maximising resource utilisation. By prioritising engagement at this critical juncture, Ardmac demonstrated how a well-coordinated design approach can significantly improve the construction process, paving the way for a more successful project outcome.

Key Features
Downflow Booth Installation
An integral component of the project was the installation of downflow booths. This system is essential for the safe handling of materials within the animal health sector, particularly for biological products. The booths, designed to operate at lower levels than the surrounding environment, employ a downward airflow mechanism. HEPA filters within the booths ensure thorough air purification, aligning with stringent industry safety regulations. The thoughtful integration of electrical and ventilation systems was executed to optimise workflow and enhance safety protocols.

Project Delivery Methodology
The 6S Approach
Employing the 6S approach—Safety, Speed, Simplicity, Savings, Sustainability, and Satisfaction—Ardmac streamlined processes and enhanced execution efficiency.

• Safety: Upholding worker well-being and stringent adherence to safety standards.
• Speed: Delivering prompt project completion without compromising quality.
• Simplicity: Reducing unnecessary complexity through streamlined procedures.
• Savings: Implementing cost-effective practices and prudent resource management.
• Sustainability: Emphasising eco-friendly solutions for long-lasting advantages.
• Satisfaction: Meeting client expectations and nurturing positive relationships.

This holistic methodology significantly enhanced the project’s overall efficiency and success.

Integrated Project Delivery
Ardmac’s commitment to integrated project delivery, from initiation to completion, played a crucial role in advancing project efficiency. Early engagement, transparency, and alignment on mutual goals resulted in innovative solutions, timely delivery, and improved quality standards throughout the construction process.

Lean Management
To facilitate the application of Lean principles, Ardmac adopted the Last Planner System (LPS) for effectively managing project timelines and quality. This structured approach involved weekly work planning, a six-week look-ahead, and daily site trade meetings for progress reviews and planning of upcoming tasks.

Outcomes
The Ardmac team succeeded in exceeding client expectations, completing all work to the highest standards while achieving zero Lost Time Incidents (LTI). Quality assurance throughout the project was exceptional, with all activities documented at elevated quality levels. The engaging involvement of seasoned team members, combined with thorough inductions for new staff, further strengthened Ardmac’s commitment to operational excellence.

Conclusion
Through meticulous planning, early contractor engagement, and a focus on integrated project delivery, Ardmac triumphantly completed the cleanroom installation for a global leader in animal health. The project not only met but surpassed client expectations, underscoring Ardmac’s commitment to quality, safety, and client satisfaction—all within a sustainable framework. This case study exemplifies Ardmac’s expertise and operational excellence in the highly regulated animal health sector.