Emergent BioSolutions | Vaccine Manufacturing Expansion

When the federal government engaged Emergent BioSolutions in June 2020 to manufacture COVID-19 vaccines at scale, the company needed to expand its manufacturing capacity immediately. Heffron deployed double-shift crews working extended hours — an unprecedented staffing commitment — to meet a timeline that had no margin. Design and construction ran concurrently, with engineers staying one day ahead of field crews as piping revisions came through in real time. The project was delivered on schedule.

Partnering with Buch as general contractor, Heffron also delivered the mechanical scope on a separate lab renovation for Emergent — isolating a viral lab from the surrounding support labs through heavy ductwork modifications and a dedicated exhaust fan, extending process gases to each lab from a centralized change-over station, and converting an existing cold box into a gowning vestibule. Casework modifications and finish, electrical, and security upgrades rounded out the build, all coordinated inside an active research environment.