Integrated Design-Build Program

Challenge

A confidential client required a multi-phase modernization and expansion program within an active operating facility. The project involved upgrading controlled environments, installing new production equipment, and expanding facility and process infrastructure while maintaining ongoing operations.

The scope included evaluating existing facility systems, identifying capacity constraints, and developing a strategy for future production growth. Because the work had to be completed in phases within a live facility, careful coordination was required to sequence shutdowns, demolition, and renovations without disrupting operations. The project also required integration of engineering, procurement, construction, and startup activities to ensure consistent quality and safety performance throughout the program.

Solution

Hallam-ICS delivered the program as an integrated design-build partner, serving as both the engineering firm and General Contractor. This delivery model allowed the team to combine engineering, procurement, and field execution under a single point of accountability.

The program began with a comprehensive facility assessment and phasing strategy. Engineers evaluated controlled-environment systems and facility support infrastructure to establish baseline performance and determine practical upgrade pathways for future equipment and production demand. A detailed phasing plan was developed to coordinate renovation activities around ongoing operations.

 Hallam-ICS then executed multiple phases of facility upgrades, including controlled-environment renovations, equipment installation, and infrastructure modernization. Work included demolition and replacement of existing spaces, installation of modular walls and ceilings, lighting and flooring upgrades, and modernization of HVAC and air distribution systems. The project also included upgrades to utility, waste, and process support systems, including pumps, tanks, piping, heat exchangers, and controls. 

 As part of a major expansion phase, Hallam-ICS designed and constructed new controlled-environment production space for owner-procured equipment, along with the utility and waste infrastructure required for operation. Temporary packaged systems were implemented to maintain continuity during renovation of existing utility areas while permanent upgrades were installed.