Case Studies

Fuijifilm ‘Northstar’ Project, Hillerød, Denmark

TEAM

Civil and Structural Engineering

Sector

Services Provided

Civil Engineering, Structural Engineering

Overview of service

ORS provided structural engineering services for the NorthStar expansion project at Fujifilm Diosynth Biotechnologies’ facility in Hillerød, Denmark, working in partnership with Fluor. The project formed part of the first phase of a major expansion to increase the site’s biopharmaceutical manufacturing capacity.

Our scope included the structural design of secondary steelwork, the review of contractor and specialist subcontractor submissions, and the assessment of temporary works proposals. ORS also provided client-side representation, specialist geotechnical advice and ongoing engineering support throughout the detailed design, pre-construction and construction stages.

The expansion introduced six new 20,000-litre mammalian cell bioreactors, doubling the facility’s production capacity and representing one of the largest biotechnology investments in Denmark.

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Farran Mullingar
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Project Outcome

The project was successfully delivered on programme through a demanding fast-track construction schedule managed by Fluor. Close collaboration between the client, design team and specialist contractors helped maintain programme certainty throughout the delivery phase.

ORS played a key role in coordinating structural design between the lead consultant and specialist subcontractors, including piling contractors, ensuring design information was delivered efficiently and integrated seamlessly with the wider project.

Once all expansion phases are complete, the Hillerød facility will become Europe’s largest end-to-end cell culture CDMO, significantly increasing production capacity and strengthening Fujifilm Diosynth Biotechnologies’ global manufacturing capabilities.

Group 4987
AK
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Challenges & Solutions

The project involved extensive coordination of structural supports for complex process equipment and building services within a highly serviced pharmaceutical environment. Construction also took place adjacent to a live manufacturing facility, requiring careful planning and coordination to minimise disruption.

Challenging ground conditions and a fast-track programme demanded close collaboration between ORS, Fluor and specialist contractors throughout the project. Early technical input, responsive engineering support and continuous coordination enabled construction to progress efficiently while maintaining programme, quality and safety standards.

ORS’ site-based engineering presence allowed design queries to be resolved quickly, supporting efficient decision-making and helping maintain progress on this complex pharmaceutical expansion.

GDCL, now part of ORS Group.

Civil and Structural Leads

Key Contacts

  • Greg Daly 4.0
    Group 8501 2
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    Greg Daly

    Managing Director

  • David McCormack 1
    Group 8501 2
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    David McCormack

    Director

  • Mark Heslin Civil Structural Lead
    Group 8501 2
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    Mark Heslin

    Associate and Civil & Structural Engineering Lead

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