UK’s first CAR-T Cell Therapy Manufacturing Facility

Merit Health has built the UK’s first CAR-T Cell Therapy Manufacturing Facility.

Using our FLEXI POD® solution, we will achieve sectional handover of the cleanroom spaces in November 2022 enabling Autolus to move in and start manufacturing life-saving therapies quicker. Our innovative solution saves considerable time compared to traditional construction, the process areas will be handed over and validated 17 months after contract award including planning and only 12½ months after site access. Compared to the industry ‘traditional’ standard of typically 4 to 5 years. We are revolutionising the construction industry using modern methods of construction and a standardised design platform to build next generation facilities. FLEXI POD® is our hybrid approach to building complex facilities offsite, with a traditional shell and core build with a POD and Pre-Assembled Module (PAM) based fit out. Using our modern methods of construction significantly speeds up the process, and for Autolus, this means that they can start manufacturing their life saving therapies much quicker than using traditional methods of construction.

We used a 650t crane which was rigged for suplerlifting. The heaviest PODs are the two electrical units that weigh 38t each. One of them is situated beyond the maximum lifting radius of the crane so will be lifted to the south electrical POD position and then using a system of runway beams and machine skates will be pulled the final 14m into position. The lifting frame used to load the PODs at the Merit factory was transported down with the PODs and used on site to lift them into position.

Over 2,000 therapies will be manufactured by Autolus a year, saving the lives of thousands of people.