Laboratory Cage Washer Replacement in an Active Research Facility
Location: United States
Industry: Research and Laboratory Facilities
Service: Design-Build Laboratory Equipment Replacement
The Situation
A research facility needed a laboratory cage washer replacement for its clean- and dirty-side processing areas. The existing equipment needed to be replaced with higher-throughput systems capable of supporting the facility’s operational demands.
The project extended beyond exchanging two pieces of equipment. Each new cage washer depended on coordinated steam, water, condensate, drainage, ventilation, electrical and compressed-air systems. Those connections had to be modified inside an occupied, secure research facility while protecting adjacent operations.
The Challenge
The work combined specialized equipment installation with the restrictions of an active facility.
Personnel, deliveries and service vendors had to comply with controlled-access, badging and escort requirements. Utility interruptions, hot work and lockout/tagout activities required advance coordination. Dust containment and floor protection were necessary on both the clean and dirty sides before demolition could begin.
Equipment access presented another constraint. The existing washers had to be disconnected and removed in sections because of facility constraints and limitations. Once the units were removed, JBrennon encountered existing pits, pedestals, drains and utility interfaces that required cleaning, investigation and restoration before the new equipment could be installed.
Field coordination continued through installation. Condensate routing, drain slopes, equipment thresholds, stainless-steel ramps and panels, backflow-preventer locations, duct configurations, compressor routing and manufacturer clearances all had to be reconciled with existing conditions.
How We Worked
JBrennon managed the project through a coordinated design-build process involving facility personnel, the design team, equipment manufacturers and the mechanical, electrical, flooring and specialty installation teams.
Before demolition, crews established plastic dust barriers and protected travel paths and working surfaces with RAM Board and Masonite. The team verified utility isolation before disconnecting medium-pressure steam, hot and cold water, condensate, ductwork, inline fan components and electrical service from the existing cage washers.
The old equipment and associated stainless-steel components were dismantled and removed in phases. After removal, the equipment pits were cleaned and inspected. Remaining pedestals and mini-columns were flush cut where permitted, drains were scoped, and deteriorated areas were prepared for repair. JBrennon then coordinated pit remediation and installation of a resinous flooring system to create a clean, durable base for the replacement equipment.
Two new Tecniplast cage washers were delivered, moved through the constrained access route and positioned in the clean- and dirty-side pits. JBrennon coordinated equipment fit-up, anchorage, stainless-steel transitions, grating and panel adjustments, entrance ramps, thresholds and separation details between the two operating sides.
Mechanical work included new and modified steam, hot- and cold-water, condensate, drain and vent connections. Exhaust ductwork and related components were modified to manage the heat and humidity generated during washer operation. Electrical work included equipment feeders, disconnects, dedicated circuits, grounding and control connections.
A Kaeser compressed-air system was incorporated to support the new washers. The compressor, electrical service, condensate drainage and compressed-air piping were installed and coordinated with the equipment controls. Piping connections were checked for leakage before startup.
Commissioning addressed the complete system rather than treating each trade independently. JBrennon coordinated water, steam, compressed-air and electrical testing; leak checks; testing, adjusting and balancing; multiple washer cycles; equipment adjustments; and manufacturer service visits. Temperature, drainage, valve, duct, sealant and pump-motor issues identified during startup were worked through until the equipment could operate as intended.
The Outcome
The client received two commissioned Tecniplast cage washer systems supported by renewed utility, ventilation, electrical and compressed-air infrastructure. Both the clean- and dirty-side systems completed operational testing, and their operating status was confirmed during project closeout.
The installation replaced aging equipment while restoring the pits, finishes and specialized interfaces surrounding it. JBrennon remained engaged through startup, vendor troubleshooting, final TAB verification and warranty-related adjustments so individual system issues did not become unresolved operational handoffs.
Project Deliverables
Two installed and commissioned Tecniplast cage washer systems
Phased removal of the existing washers and abandoned utility connections
Clean- and dirty-side containment and protected access routes
Remediated equipment pits with restored resinous flooring
Modified steam, water, condensate, drainage and vent systems
Coordinated exhaust ductwork and ventilation connections
New electrical feeders, disconnects, dedicated circuits and grounding
Installed Kaeser compressor and compressed-air distribution system
Completed stainless-steel transitions, grating, panels, ramps and thresholds
Water, steam, air, electrical, cycle and TAB testing across the integrated installation