Arrowhead Pharmaceuticals specializes in genetic treatment of diseases. They develop medicines that treat intractable diseases by silencing the genes that cause them.

Their new 13-acre  Verona campus will consist of two buildings: building 1A which is 142,000 square feet of half laboratory space and half office space, and building 1B which is 146,000 square feet of a cGMP laboratory. Westphal & Company was selected due to our past work with Arrowhead facilities and other pharmaceutical cGMP facilities, both laboratory and manufacturing. 

The Arrowhead campus in Verona is a greenfield site. Westphal was tasked with providing a campus-wide medium voltage distribution system and full campus power backup via (2) 2.5MW and (1) 2MW generators. Westphal will also be a design-build partner on Building 1A responsible for the design of normal and life safety branch power, lighting, lighting control, site and parking lot lighting for the entire campus, and fire alarm system including a smoke evacuation system.

This multi-phased project consist of new labs with clean rooms and process for the use in developing vaccines for animals of the fowl, swine and cattle families in this 55,000 square foot facility in Verona, WI. This phased project is being completed to allow the facility to continue to produce these vaccines insuring the power to freezers and test equipment stayed active during construction. There are plans to expand this facility in to green space adjacent to the current facility. The initial design was completed by GBA Architects of Lenexa, KS and Westphal assisted in making available power and control for the equipment coming from other plants.

Anticipated completion of the renovated area is December 2021.

Catalent is a pharmaceutical company located on Madison’s west side. The Train 4 & 5 Addition at Catalent is made up of 70,000 square feet consisting of 8 clean rooms, a freezer farm, coolers, explosion proof storage, warehouse, loading dock, and mechanical mezzanine. The biggest challenge for this project was routing the branch conduit from the electrical room to the clean rooms through the inaccessible ceiling. Our Virtual Design Construction/BIM team spent many hours detailing the conduit racks to ensure they had adequate capacity as well as coordination with other trades. Our Prefabrication team used these drawings to make the elaborate conduit racks a reality, while our crews on site efficiently installed it all. Commissioning and validation of these systems was tracked through CxAlloy. We combined our proprietary quality control best practices with the General Contractor’s and Catalent’s quality team requirements to deliver a very smooth commissioning process.

Stratatech, a company founded in Madison, is developing regenerative skin tissue for burn victims. This project consisted of a 27,000 square-foot addition to the client’s existing building, plus remodeling 5,000 square feet of existing space. We provided lighting, power, IT infrastructure, and temperature controls for the building. The building addition included cold storage, quality control suites, product testing, offices, mezzanine mechanical space, shipping, additional power, and emergency backup. The challenge of this project was integrating the existing building into the new addition while the customer remained in operation. Communication and detailed coordination with the owners and Westphal & Co. resulted in minimal disruption,  no loss of power to critical manufacturing, and a successful project.

This project consisted of a complete interior demolition and build back of a 30,000 square-foot facility, plus a new 4,700 square-foot penthouse added to the existing structure. We collaborated on this Design/Assist project with FCDI, Flad, AEI and Vogel to provide a final product that met the user requirement specification (URS), budget, and schedule.

Our BIM team was involved early to solve complicated issues of routing all the systems through the existing wood trusses, as well as wall rough-ins for the cell processing suites. The Prefabrication team then used the BIM drawings to kit each room with the required wall rough-in boxes and colored conduit. All material was delivered to the project sealed and that seal was maintained throughout construction to reduce dust inside the conduit, light fixtures, and devices. The project is made up of cGMP processing suite, QC and production labs, offices, warehouse, cooler, and a mechanical penthouse. The electrical scope includes LED lighting, nLight controls, generator, uninterruptible power system, and fire alarm. Our Globalcom Division performed all of the low voltage work on this project: fiber, cameras, access control, door interlocks, and structured cabling. Our controls division was also a part of this project working directly for Automated Logic Corporation.

This 32,700 square-foot isotope production facility will use a patented, proprietary manufacturing process to produce medical isotopes such as molybdenum-99 (moly-99), the essential component in medical imaging procedures used to diagnose heart disease and other conditions.  We will install over 17,000 feet of conduit in the concrete floors and walls of the facility.  All conduit is galvanized rigid steel, mostly 2” or larger.  These conduit racks and runs have exclusively been built in our prefabrication facility. QA/QC is critical on this project as embedded conduit has to be within ½” tolerance of designed locations. Large multi-conduit assemblies are prefabricated and shipped to the jobsite, where they are picked by crane and set in place for final assembly. The significant prefabrication is critical because minimizing the labor on-site allows us to avoid the high potential for personal injury that can occur on such a project.