Optimizing Logistics and Foundation Solutions for Seqirus’ cGMP Warehouse Expansion
KEY TAKEAWAYS
CLIENT PURPOSE + PROCESS
Seqirus required a 48,000-square-foot cGMP Warehouse Expansion to support the increased production demands associated with the recent addition of a second production line in their Fill-Finish facility, which enables the formulation and filling of cell-based influenza vaccines in pre-filled syringes for global distribution.
The new warehouse provides Seqirus with approximately 23,000 square feet of ambient storage and 12,000 square feet of cold storage, accommodating current and future pallet storage needs to ensure smooth operations. The facility also includes mechanical and electrical utility mezzanines, utility and fire pump rooms, and corridor and vestibule spaces designed to optimize flow and functionality.
To support Seqirus’ storage density requirements, the facility features 46-foot-high racks with wire-guided Raymond Swing Reach Trucks for efficient product handling. The warehouse floor was also constructed with advanced flatness levels to meet precise operational standards.
Ancillary upgrades included a 2.5 MW emergency generator for increased resilience and reconfigured loading dock spaces to streamline logistics. This comprehensive expansion ensures that Seqirus has the capacity, infrastructure, and storage flexibility needed to meet growing global vaccine demands.
As one of the largest influenza vaccine providers in the world, Seqirus plays a crucial role in the global prevention of influenza. Their mission is to reduce the severity and impact of influenza, which can have life-threatening consequences. Each year, their vaccines help protect millions of people. Seqirus is dedicated to advancing vaccine technology and research, ensuring the highest standards of safety and efficacy. They are committed to continuous innovation, collaborating with healthcare professionals and organizations worldwide to improve influenza prevention strategies. Seqirus contributes significantly to global health security and the well-being of communities worldwide.
PROJECT OVERVIEW
CHALLENGE I
The new building’s foundation required significant preparation to align with the existing campus buildings. Approximately 12 feet of fill, totaling 17,365 cubic yards, was needed to raise the building pad to the appropriate elevation.
SOLUTION I
To meet this challenge, 1,447 truckloads of fill were delivered to the active campus. The building pad was constructed beyond the necessary depth and allowed to settle and compact naturally over a four-week period. Drone mapping technology (Propeller) was used to monitor settlement and ensure precise leveling. To provide additional support, 475 aggregate piers were installed, including 345 geopiers and 130 grouted ground-impact piers, ensuring a stable foundation for the facility.
CHALLENGE II
The material laydown area was restricted to a 20-foot perimeter on two sides of the building pad, limiting available space for staging. Additionally, the height of the pad and slab left only one entry point for all interior construction materials, creating a potential bottleneck for material handling and building access.
SOLUTION I
Careful coordination and continuous adjustments to the site logistics plan were critical to avoiding congestion and ensuring smooth operations. BE&K prioritized safety through mandatory site/safety orientation training for all workers before accessing the site. Off-site prefabrication was also leveraged to reduce on-site material handling, streamlining construction and minimizing disruptions. This strategic preconstruction approach ensured efficient workflows and a successful project outcome.
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