Case Studies

Civil & Structural for the Pharma Industry

TEAM

Civil Structural

Sector

Services Provided

Civil & Structural Services for Pharmaceutical Projects

Overview of service

In partnership with a leading pharmaceutical managed services client, ORS provided critical civil and structural services for the detailed design and construction stages of a new production facility in the west of Ireland. This high-profile project required significant modifications to an existing structure to house a new pharmaceutical fill line.

The scope of work included extensive demolition and strip-out works, installation of new foundations, support frames, process tanks, drainage systems, and other essential infrastructure such as roof plant, clean rooms, and ancillaries. The objective was to adapt and upgrade the existing facility to meet the rigorous standards of a cutting-edge pharmaceutical production line while overcoming the unique challenges associated with modifying an existing building.

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Farran Mullingar
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Through strategic design and meticulous coordination with other design disciplines and stakeholders, ORS successfully delivered the detailed design phase to meet the tight programme, while adhering to the complex requirements of a high-specification pharmaceutical environment.

The design process highlighted ORS’s expertise in integrating and working with existing facilities and balancing technical precision with efficient project flow. The use of cloud-based project management software such as Bim 360 allowed the design team to share live updates, communicate seamlessly, and make quick adjustments, ultimately enhancing project quality and coordination.

Notably, the project fostered a strong sense of collaboration between all parties involved, including civil & structural, architectural, process, and mechanical & electrical teams. This high level of multidisciplinary collaboration resulted in a well-coordinated design, meeting both the client’s and industry’s high standards and minimising issues during the construction phase.

Group 4987
Castleforbes 3
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Project challenges

Challenges & Solutions

The project’s tight timeline necessitated continuous coordination and a proactive approach to keep the design on track. ORS assigned senior engineers and experienced technicians to manage the design phase efficiently, allowing the team to address emerging challenges without delaying progress. Utilising BIM 360 and Navisworks, ORS kept all project data centralised, enabling real-time communication and immediate problem-solving.

Limited structural information was available on the existing facility and there were uncertainties regarding foundations, framing, and substructures. ORS, in collaboration with the design team, tackled this challenge by initiating thorough site investigations and surveys. The design team procured ground-penetrating radar (GPR) scans, CCTV surveys, and measured building surveys to help close information gaps. These surveys were mapped into a centralised federated 3D model, allowing for a comprehensive view of the facility’s substructure and helping the team identify any critical issues early in the design process.These sub-consultants are tried and tested on multiple projects of this scale, which means that the overall project team worked cohesively.

This project stands as a testament to ORS’s capability in handling complex, high-stakes pharmaceutical projects with both technical precision and collaborative agility. By effectively addressing unique project challenges, ORS successfully met client requirements and established a streamlined design that meets the evolving demands of the plants operation. This case study underscores ORS’s commitment to delivering high-quality outcomes within the demanding parameters of Ireland’s growing pharmaceutical sector.

Leads

Key Contacts

  • David Mc Cormack Director
    Group 8501 2
    View Bio
    David McCormack

    Director

  • Mark Heslin Civil Structural Lead
    Group 8501 2
    View Bio
    Mark Heslin

    Associate and Civil & Structural Engineering Lead

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Talk to A specialist

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Contact us

Block A, Marlinstown
Business Park, Mullingar,
Co.Westmeath,
N91 W5NN

Pembr, 127 Baggot Street Lower, Baggotrath, Dublin, D02 F634

Portershed,
Eyre Square,
Galway,
H91 HY51

Office 4, Spencer House,
High Road, Letterkenny,
Co. Donegal,
F92 PX8N

Unit W9B,
Ladytown Business Park, Naas,
Co. Kildare,
W91 PC62

ORS has satellite offices in Tullamore and Maynooth.

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