The University of Chicago Kovler cGMP Laboratory:
Converting Basement Space to BSL-3 and Class 10,000
Michael Yoshimura, AIA, OWP/P
Chicago
This $2.1 million Kovler Hall upgrade provides The University of
Chicago Biological Sciences Division (BSD) with a high-purity clinical
Good Manufacturing Practices (cGMP) facility that will support the
development and clinical trialing of new groundbreaking technologies
in the areas of stem cell pancreatic islets, dendritic, hepatic,
and bone marrow applications. The facility is a Biological Safety
Level-3 (BSL-3), Class-10,000 stem cell production lab that provides
the stringent clean room environment to limit particle interference
so the outcome of the cell and gene therapy work is not affected
by impurities.
This project required the design team to convert an underutilized
basement space below existing labs within a two-story building into
a cGMP biological pilot plant providing the stringent clean room
environment required for cell and gene therapy work. Technical performance,
process and cost controls, timeliness, and a high level of service
resulted in two high-purity cGMP lab suites.
With a collaborative team approach, this challenging project met
the rigorous FDA standards for clean room construction. Our procedures
proved so effective that the testing and certification process determined
that, in addition to easily meeting all the targeted Class-10,000
requirements, the lab met two of the three parameters for a Class-1,000
space.
Phil Lasarsky of Steve Rosenstein & Associates, the lab planner
who collaborated with us on this project has said:
"With an intense schedule and a level of complexity not
usually encountered, the quality of construction was beyond our
expectations. We believe the facility will become the benchmark
the industry will want to emulate."
Findings:
Indoor air quality was an important consideration on this project
to support the occupants' work in a cGMP Class-10,000, BSL-3 environment.
The lab spaces were designed at air change rates higher than required
by the City of Chicago Building Department and the Illinois Department
of Public Health, and were designed to comply with the current ASHRAE
62 indoor air quality standard, and the current ASHRAE 55 thermal
comfort standard. The design air change rates also meet the current
needs and anticipate the future needs of the lab suites.
One of the key challenges to the project was to minimize disruptions
to the existing Kovler Building's occupants and systems, specifically
the lab space located directly above our proposed lab suites. Compounding
this issue was the need to design a cleanroom ceiling without any
access doors and a low floor to floor height of 12"-0".
These space constraints required locating the new exhaust air dampers
and air valves in congested existing mechanical spaces; the creative
use of existing chases for the new supply air and BSC exhaust air
ductwork; the creation of two new chases for the general lab exhaust
air ductwork and the creation of a new mechanical penthouse to locate
the new supply air dampers, hot water reheat coils and air valves.
As a result, we were able to work around the existing lab space
on the floor above, except for the creation of two chases in the
men's and women's locker rooms. We were successful in maintaining
the operation of the existing lab with only minor inconveniences
to the occupants outside of the lab.
Labs21 Connection:
The construction process was especially demanding because of the
extreme standards of cleanliness required to obtain certification
of the finished facility, and because of the stringent documentation
procedures established for each phase of the work. Every tradesman
received advance training and instruction on the strict guidelines
required for working within the area. Each separate piece of ductwork
was fabricated, numbered, cleaned and sealed offsite, then cleaned
again before being brought into the space, unsealed at one end,
installed, and written off the check list.
Addition of more sophisticated controls and monitoring/measuring
equipment allows the system to react to the actual demand conditions
and to be more energy efficient; allows for daily system adjustments;
allows preventive maintenance to occur; reduces costly repairs;
and prolongs the life of the equipment. The new head end control
system for the cGMP Lab was interfaced with the existing campus
building automation system to eliminate the need for a 24/7 on-site
building engineer.
The scope of this project did not provide us with an opportunity
to make an environmental impact in terms of reducing CO2 and CFC
emissions. However, our design did have an environmental impact
in terms of the specified zone pressurization controls and fume
hoods ensuring contamination control and greater occupant safety.
(By definition, BSL-3 labs are areas where work is done with indigenous
or exotic agents that can cause lethal or serious disease through
inhalation.) As noted, 100% outside air was used to maximize dilution
of harmful airborne contaminants. The specified exhaust fans have
a very high effective stack height to avoid re-entrainment of air
into the building.
Biography:
Michael S. Yoshimura, AIA-In more than 20 years of working
with The University of Chicago, one of the premier research institutions
in the nation, Mike has developed extensive laboratory credentials.
In 1997 and 2002, he added to his existing credentials with studies
in laboratory design at Harvard University's School of Public Health
and Graduate School of Design. Mike's experience in developing laboratory
environments is second-to-none and is displayed in his work with
University of Chicago Hospitals, Northwestern Memorial Hospital
and the University of Illinois at Chicago. A principal of OWP/P,
he is a licensed professional architect and a member of the American
Institute of Architects and the Society for College and University
Planners.
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