Sector

Merit Transforms Cell & Gene Therapy Landscape with Rapid Expansion of CGTC Facility

Cell & Gene Therapy Catapult (CGTC) stands as the UK’s flagship facility dedicated to advancing cell and gene therapies. This government-backed initiative supports CGT companies in progressing their therapies from initial stages through to clinical trials, before transitioning to dedicated manufacturing sites.

Merit proudly served as the Principal Contractor for the expansion project, designing and delivering an impressive 1,800m2 of GMP space, featuring six 200m2 modules. The project was completed within a remarkable 40-week timeline from contract award to Operational Qualification (OQ).

The CGTC project marked a major milestone in Merit’s innovative approach to offsite facility design, as the team utilised a platform design which set the foundation for future repeatable facility design.

Merit’s comprehensive scope for CGTC encompassed the design and development of process areas, along with civil, structural, architectural and MEP systems. The facility was designed to meet Grade B standards and BSL 2 containment.

Furthermore, this project exemplified our commitment to quality through extensive collaboration with the client. Detailed discussions and extensive workshops focused on critical aspects to ensure that the facility would meet the highest operational and compliance requirements.

Client: Cell & Gene Therapy Catapult
Location: Stevenage
Sector: Life Sciences
Project: Expansion Phase 2

Key Features

Merit was tasked with both validating the design for Phase 2 and providing a fixed price lump sum through open book tendering.
Works delivered in complex GMP facility.
MHRA licensed facility.
Project within large scale operational campus requiring constant stakeholder engagement and traffic management to avoid business interruptions and ensure staff safety.
Large proportion of works self-performed by Merit including MEP and cleanroom, significantly reducing schedule and quality risk.

Key Outcomes

Achieved ISO5 Class 100 standards (Grade B ‘At Rest’, Grade C ‘In Operation’) according to ISO 14644.
Provided containment for Biosafety Level 2 (BSL2).
Reduced on-site personnel by 70% through offsite construction, lowering facility carbon footprint and enhancing health and safety.
Utilised a Pre-Assembled Modules (PAMs) approach with 60% of construction completed offsite at Merit’s Cramlington-based smart factory.
Implemented self-delivered MEP and cleanroom construction, saving 10% of project value by eliminating Tier 2 overhead costs and reducing management interfaces.
Increased UK equipment content for enhanced cost-efficiency, quality and schedule improvement.