CSL Behring Building 4 Replacement Project

Client: CSL Behring

Location: Kankakee, IL, U.S.

Map showing the location of CSL Behring Building 4 Replacement Project

Executive Summary

Fluor provided engineering services for CSL Behring's plasma fractionation facility expansion, including a seven-story manufacturing facility, warehouse space and plant utilities buildings.

The project was an expansion of CSL Behring's existing blood plasma fractionation facility in Kankakee, Illinois. The expansion increased the production of plasma intermediates. The expansion processing capacity was initially 4 million liters of plasma annually, expandable to 12 million liters of plasma annually.

Client's Challenge

CSL Behring is a global biotechnology leader specializing in developing products to treat coagulation disorders, primary immune deficiencies, hereditary angioedema, inherited respiratory disease and neurological disorders. CSL Behring's products are also used in cardiac surgery, organ transplantation, burn treatment and to prevent hemolytic disease of the newborn.

The expansion was needed to support the growing need for its life-saving and life-improving therapies used to treat patients with rare and serious medical disorders around the world. The expansion would add approximately 300,000 square feet to the site. The cross-functionality that would be enabled by the capacity increase would allow CSL Behring to leverage its global manufacturing network, helping to optimize the manufacturing efficiencies of immunoglobulin and albumin.

Fluor's Solution

We assembled a team experienced at global life sciences projects and provided early planning, conceptual, basic, detailed engineering and construction support for CSL Behring's Kankakee expansion. The facilities include one 174-foot-tall, seven-story manufacturing facility, an adjacent clean utilities facility, a single story plant utilities facility and a connecting pipe bridge/rack.

Major buildings and facilities in the expansion project include:

Building 33, the main processing building, including space to more than double the capacity and deemed one of Illinois' tallest structures south of Chicago
Building 34, an attached warehouse and clean utilities building, extending south of Building 33
Building 35, a plant utilities building housing ammonia-based chillers providing cold glycol and compressed air for the needs of Building 33 and 34, and a pipe rack to Building 33/34
Site modifications, including connections to provide power, potable water and other utility services to the building from other areas of the existing plant

The design was executed with our Greenville, South Carolina, office as lead office and support from the Gliwice, Poland, office. Starting the planning and conceptual design activities in the 2nd quarter of 2014, and the construction activities five months later, the engineering design was completed in 18 months. we continued to provide home office construction support services during 2017 until project completion.

Conclusion

We provided engineering services for CSL Behring's plasma fractionation facility expansion to support the delivery date. The expansion increased the plasma intermediates production capacity at the facility for CSL Behring's biotherapeutics production.