cGMP Advanced Manufacturing Area for Orthoplastics

PROJECT OVERVIEW

Orthoplastics is a global leader in the development and manufacture of orthopaedic implants and components, helping surgeons transform lives around the world. This project, the first phase of a fit out programme for a new facility in Bacup, Lancashire, involved the delivery a new cGMP advanced manufacturing area for the production of Ultra High Molecular Weight Polyethylene (UHMWPE) sheets used in the manufacture of orthopaedic implants.

The requirement was for a production area that can provide a controlled environment, isolated from the rest of the floorplate, during processing periods, while enabling access by a remote controlled mobile crane to remove the completed UHMWPE sheets when the equipment is non-operational.

PROJECT SPEC

The new Orthoplastics building is a single storey facility and the size and weight of the UHMWPE equipment required excavation of additional space below ground to accommodate both the machine and the building services required to process materials at up to 2400C. The 1000m2 processing area needs to be a cleanable cGMP compliant environment to avoid the risk of contaminants in materials that will be used in orthopaedic surgery.

The partitioning for the perimeter is 11m tall and connected to the ceiling of the existing building shell. To provide the structural stability required for such tall walls, the standard Norwood 100mm Mediline partition thickness has been increased to 200mm. The project also included rapid rise doors for access by the remote control crane that removes the large UHMWPE sheets following the process.

The fully demountable double skin bi-panel system enabled a fast and robust installation enabling the project to get back on track quickly following interruption by the pandemic. The panels were prefabricated in-house by Norwood, enabling a fast-track installation programme.

Norwood was also designed, manufactured and installed a range of their single and double steel doors in blue.