Polypeptide Novavax – Operation Warp Speed
As part of the federal Operation Warp Speed initiative, Polypeptide Laboratories needed to rapidly expand its manufacturing capacity to support Novavax’s vaccine production. As a design build subcontractor to CRB, Pacific Rim Mechanical (Pac Rim) was engaged to deliver a new ISO 8 cleanroom and utility systems capable of meeting pharmaceutical-grade performance—on an aggressive six-month schedule and under the unprecedented conditions of the COVID-19 pandemic.
The $5.1 million project included validated 316L stainless-steel solvent systems, integrated solution mixing tanks, advanced HVAC and filtration, waste-handling infrastructure, and full critical-utility integration—all designed, built, and commissioned to cGMP standards.
Challenge
Speed was non-negotiable. With federal and commercial milestones tied to vaccine readiness, every day mattered. The project required just-in-time delivery of long-lead equipment, overlapping construction phases, and continuous adaptation to evolving health-and-safety protocols—all while maintaining cleanroom compliance.
Solution Delivered
Pacific Rim Mechanical established a detailed fast-track execution plan that integrated procurement, prefabrication, and installation workflows from day one. Prefabricated piping assemblies, pre-tested utility skids, and synchronized vendor deliveries eliminated delays and rework.
Despite pandemic restrictions, the team maintained daily coordination across trades and suppliers through virtual planning sessions, real-time schedule updates, and strict on-site safety protocols. This proactive approach kept all stakeholders aligned and installation activities progressing without interruption.
Outcome
The new cleanroom was completed safely, fully validated, and on schedule—enabling Polypeptide to accelerate vaccine production and meet national delivery commitments. The project demonstrated how rapid execution and technical precision can coexist in the most demanding conditions, and it established a foundation for multiple follow-on projects with equally challenging timelines.
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