PC3   Laboratory,   School   of   Veterinary   Science,   James   Cook
University.
Completed   in   2010   by   Cockram   Construction.
2

Cockram’s   reputation   for   delivering   facilities   of   the   highest   standards   in   construction   and   technical   excellence   is   well   deserved.
Due   to   our   proven   expertise   in   the   areas   of   laboratory   and   bio ‐ pharmaceutical   facilities,   in   the   fields   of   clean   room   design,   construction,   commissioning   and   validation,   we   have   seen   our   operations   expand   globally   as   a   result   of   client   demand   from   around   the   world.
Cockram’s   team   includes   construction   and   technical   professionals   who   have   considerable   experience   in   the   delivery   of   Physical   Containment   laboratories   (PC
Laboratories).
This   guide   has   been   prepared   to   share   some   insights   into   the   requirements   for   the   design,   construction   and   testing   of   physical   containment   laboratories.
This   is   not   an   exhaustive   technical   resource   for   PC   laboratory   design,   construction   and   testing.
It   is   simply   to   provide   a   useful   resource   within   Cockram   and   also   externally,   to   industry   professionals   who   are   directly   involved   in   the   design,   delivery   and   ongoing   management   of   this   type   of   facility.
We   hope   that   you   find   this   guide   to   be   of   value   as   you   plan   for   your   next   PC   laboratory   project,   and   we   encourage   you   to   contact
Cockram   Construction   directly   if   we   can   be   of   assistance   to   you   in   the   planning,   design,   construction   and   facility   delivery   processes.
Mal   Batten
Managing   Director
Cockram   Construction   mal.batten@cockram.com
3

4

Physical   containment   or   ‘PC’   is   a   reference   in   the   Aus ‐ tralian/New   Zealand   Standards   (AS/NZS   2243.3:
2010—Safety   in   laboratories  ‐  microbiological   safety   and   containment)   to   the   level   of   risk   associated   with   microbiological   work.
This   recognises   four   levels   of   physical   containment.
They   are:
PC   1:

Practices   &   equipment   appropriate   for   student   and   undergraduate   teaching   laboratories
 Risk   Group   1   as   per   the   Standard

Work   that   may   be   carried   out   on   an   open   bench

Organisms   not   known   to   cause   disease   in   healthy   adults
PC   2:

Practices   &   equipment   applicable   for   clinical,   diag ‐ nostic,   industrial,   teaching,   and   related   purposes

Risk   Group   2   as   per   the   Standard

Work   is   with   micro   organisms   which   may   be   pre ‐ sent   in   the   community

Micro   organisms   which   may   be   associated   with   animal,   plant   or   human   disease   of   moderate   sever ‐ ity
 Work   which   may   be   carried   out   on   an   open   bench
with   good   microbiological   technique

If   there   is   significant   risk   from   aerosols,   a   biological   safety   cabinet   shall   be   used
5

PC   3:

Practices   &   equipment   applicable   for   clinical   and   diagnostic   work,   includes   indigenous   or   exotic   micro   organisms

Risk   Group   3   as   per   the   Standard

Risk   of   serious   infection   to   humans,   animals   and   plants

Safeguards   such   as   airlocks,   door   seals,   security,   decontamination,   pressure   steam   sterilisation,   waste   treatment,   alarms   &   additional   communica ‐ tion   systems
PC   4:

Practices   &   equipment   applicable   for   dangerous   micro   organisms   posing   a   high   individual   risk   of   life ‐ threatening   disease

Risk   Group   4   as   per   the   standard

Life ‐ threatening   diseases   that   may   be   spread   to   the   community

Isolated   from   other   laboratories

Clothing   change   and   shower   rooms   contiguous   to   ventilation   system

Liquid   waste   decontamination   required

Work   completed   using   a   Class   III   biosafety   cabinet
(exhausts   venting   outside   the   laboratory)   or   fully   encapsulated   positive   pressure   suits
6

Summary   table   of   PC   laboratory   risk   gradings
Level   PC1   PC2   PC3   PC4
Risk   within   the   facility
Low   Low   to   moderate
High
Risk   outside   the   facility   (to   broader   com ‐ munity)
Example
Low   Limited   with   low   risk   of   spread
Limited
Non   pathogenic   bacteria
Hepatitis,   salmonella
SARS,
Yellow   fever.
High
Readily   spread
Hendra   virus,
Ebola   virus
PC4   laboratory,   Victorian   Infectious   Diseases   Research
Laboratory,    by   Cockram   Construction.
7

Fully   welded   stainless   steel   exhaust   ducts   with   carbon   filtration,   installed   by
Cockram.
Complex,   intense   negative   pressure   systems   such   as   this   are   typical   of   many   PC4   or   high   end   PC3   projects.
8

The   standards   required   of   PC   laboratories   are   rigorous,   and   post   construction   certification   of   the   facility   may   not   be   achieved   if   sufficient   steps   aren’t   taken   during   the   design   and   construction   phases   to   identify    the   requirements   for   certification.
In   our   experience,   the   following   provides   a   useful   checklist   for   client   teams   when   preparing   to   deliver   a
new   PC   laboratory:
1.
Engage    experienced   architectural   and   engineering   teams,   suited   to   the   scale   and   complexity   of   the   project
2.
Consult   early   with   the   Australian   Quarantine   &
Inspection   Service   (AQIS)   (where   applicable)
3.
Consult   early   with   the   Office   of   the   Gene
Technology   Regulator   (OGTR)
4.
Understand   ALL   of   the   applicable   standards,   and   any   foreshadowed   changes
5.
Correct   classification   within   each   QC   or   PC   level   is   essential
6.
Mechanical   and   electrical   specifications   will   vary   on   interpretation
7.
Be   aware   of   latest   equipment   options
9

Vinyl   floors   are   laid   to   avoid   sharp   angles   and   recesses   where   contaminants   can   be   trapped   and   floors   are   sealed   to
10
minimise   any   leakage.

This   brief   summary   of   construction   techniques   critical    for   the   correct   delivery   and   certification   of   PC   labs    is   not   intended   as   an   exhaustive   checklist.
Rather,   it   is   intended   to   give   readers   an   insight   into   some   of   the   design   and   construction   features   of   PC   labs   that
deserve   close   attention.
It   is   also   important   to   understand   that   PC3   and   PC4   laboratories   must   be   physically   separated   from   other   areas   and   that   specific   signage   is   required   for   PC
laboratories.
Walls   &   Ceilings
There   are   generally   three   types   of   material   used:

Insulated   Panel

Multi ‐ layered   plasterboard

Masonry
Cockram   typically   prefer   to   work   with   insulated   panels   because   they   can   be   sealed   more   efficiently   than   alternative   materials.
Extra   precautions   are
required   if   working   with   plasterboard   or   masonry.
11

Above   and   below.
Prior   to   installing   walls,   base   channels   should   be   thoroughly   coated   with   polyurethane   sealant.
12

Above   and   below.
Pictured   are   samples   used   on   the   University   of
Auckland   PC3   laboratory   project   by   Cockram.
The   images   illustrate   the   panels,   joints   and   sealing   techniques   which   were   used   in   lieu   of   the   original   plasterboard   design.
13

Doors   and   windows
For   PC   labs,   all   doors   and   windows   are   generally   of   stainless   steel   construction.
They   are   typically   provided   by   a   specialist   manufacturer   and   are   designed   and   manufactured   to   suit   the   particular   level   of   PC   laboratory   they   are   intended   for.
Doors   and   windows   are   generally   interlocked   and   alarmed.
Higher   grade   PC   labs   (PC3   and   PC4)   require   very   high   standards   of   lab   entry   doors   and   door   sealing   systems
(such   as   pneumatic   seals).
Air   lock   doors   to   PC3   laboratory   completed   by   Cockram   in   2010.
14

Above:   A   pass   through    de ‐ contamination   unit   fitted   in   a
PC3   area   requires   a   sophisti ‐ cated   barrier   seal.
Left:   Air   lock   doors,   such   as   this   one   installed   at   Auckland   Univer ‐ sity   by   Cockram,   are   highly   complex   installations   which   require   particular   care   and   specialist   expertise.
15

Access   to   PC   labs   is   typically   controlled   via   push   button   controls
(above)   or   electronic   swipe   cards   which   restrict   unauthorised   access.
Windows   (below)   are   sealed   and   doors   are   alarmed   to   alert   for   any   falls   in   pressure   which   may   affect   the   containment   capabilities   of   the   laboratory.
16

Joinery
Joinery   for   PC   labs   must   be   designed   with   ease   of   cleaning   and   hygiene   standards   top   of   mind.
Joinery   should   be   smooth   and   impervious   to   moisture,   chemicals   or   cleaning   agents.
Bench   tops   must   not
have   open   seams.
Joinery   should   not   contain   any   enclosed   spaces   or   voids   where   fumigants   or   contaminants   may   be   trapped.
Joinery   must   be   designed   with   ease   of   cleanliness   foremost   in   mind.
PC   labs   will   also   contain   a   variety   of   specialised   equipment   and   laboratory   users   are   trained   in   maintaining   both   equipment   and   surfaces   etc   to   high   standards   of   cleanliness.
17

Mechanical   systems
PC   laboratories   require   a   constant   negative   internal   pressure   relative   to   external   air   pressure.
This   is   needed   to   maintain   the   containment   of   the   laboratory’s   micro   organisms   (to   prevent   escape).
This   constant   negative   pressure   reflects   on   the   design   of   all   mechanical   systems   where   there   is   a   penetration   from   outside   to   inside   the   laboratory.
PC2   laboratories   have   no   mandated   minimum   inward   airflow   pressure   differential.
PC3   and   PC4   laboratories   require   a   minimum   of   50   Pascals   and   25
Pascals   between   adjoining   rooms   of   the   facility   (a   pressure   cascade).
The   use   of   bubble   style   dampers   are   required   in   PC3   and   PC4   facilities.
All   ductwork   must   be   pressure   tested   using   a   duct   work   integrity   test   (pressurised   to   1,000   Pa   with   zero   leakage   over   three   minutes   between   the   lab   room   and   the   HEPA   filter   canisters   for   PC3   and   PC4   labs).
Fully   welded   stainless   steel   construction   is   often   a   require ‐ ment   of   PC   lab   mechanical   ser ‐ vices.
18

PC   labs   also   require   dedicated   vacuum   systems   and   no   recirculation   of   air   is   allowed   to   non   containment   areas.
Stand   alone   HVAC   systems   are   usually   used.
HEPA   filter   boxes   need   to   be   pressure   tested   with   a   zero   leakage   requirement   and   have   the   ability   to   withstand   a   pressure   of   2,500   Pa.
Air   movement   within   the   PC   area   should   be   from   the   cleanest   to   the   potentially   more   contaminated   areas.
250   micron   screens   fitted   to   PC   laboratory   exhaust   (left)   and   air   supply   (right).
Alarms   and   monitoring   systems   are   required   to   maintain   vigilance   over   the   control   of   negative   pressures   of   PC   laboratory   environments.
19

In   summary,   typical   mechanical   systems   requirements   of   PC   laboratories   include:

HEPA   filtration

Interlocked   air   supply   and   exhaust   to   ensure   inward   flow

Fully   welded   stainless   steel   construction

100%   exhaust   to   atmosphere

Fumigation   regimes
Labs   should   also   feature   audible   alarm   systems   and   pressure   displays   so   that   the   negative   pressure   status   is   constantly   monitored.
Welded   stainless   steel    ductwork.
20

Hydraulic   systems
Hydraulic   systems   within   PC   laboratories   should   be   designed   with   the   following   in   mind:

Hands ‐ free   operation   at   washing   stations

Safety   showers   –   no   floor   waste

Back ‐ flow   prevention   (use   of   R.P.Z.
devices)
 Fully   sealed/welded   trade   waste   pipe   systems   and   double   containment   pipe   systems

Approved   waste   regime
Waste   removal   is   performed   frequently   via   a   sealed
container.
Part   of   the   waste   decontamination   system   for   a   PC3   Lab   completed   by   Cockram   in   2010.
21

Above:   Waste   treatment   via   a   sealed   container.
Below:   HEPA   filter   boxes   installed   in   a   plant   room   adjacent   to   a   PC3   laboratory.
22

Electrical   systems
Electrical   systems   design   for   PC   labs,   as   with   hydraulic   systems,   should   provide   for   the   following:

Back ‐ up   power   for   the   ventilation   system.
This   is   strongly   recommended

Back ‐ up   power   for   Biological   Safety   Cabinets
(BSCs)

Ducted   systems

Warning   systems   –   designed   for   both   occupants   and   equipment.
Penetrations   associated   with   electrical   systems   should   be   minimal,    sealed   and   have   a   single   point   of   entry   for   each   cable.
Complex   electrical   services   are   a   feature   of   PC   lab   design.
23

Laboratory   equipment
PC   laboratories   feature   advanced   biological   equipment   and   every   laboratory   will   feature   different   equipment   depending   on   the   nature   of   its   use.
Biological   safety   to   lab   users   is   the   one   constant   irrespective   of   lab   equipment.
As   a   general   rule:

Autoclaves   must   be   fitted   with   bioseals   in   PC3   and
PC4   laboratories

For   PC4   labs,   protective   suits   with   air   breathing    systems   and/or   isolators   are   required

Positioning   of   BSC’s   should   bear   in   mind   supply   and   return   air   locations
 Provision   should   be   made   for   automatic   shutdown   of   sterilizers

Identify   equipment   requiring   back ‐ up   power— freezers,   ovens , etc
User   safety   is   a   constant   and   paramount   concern.
24

25

The   greatest   challenge   with   wall,   floor   or   ceiling   penetrations   in   a   physical   containment   environment   is   obvious:   every   penetration   increases   the   risk   of   an
air   leak.
PC3   and   PC4   labs   cannot   have   air   leaks   greater   than   2
litres   per   second.
Trying   to   find   a   leak   and   rectify   it   post   construction   can   be   arduous   and   expensive.
This   means   that   every   penetration   of   every   type—   electrical,   hydraulic,   mechanical,   fire   services   etc— must   be   fully   sealed.
It   is   advisable   that   penetrations   through   surfaces   are   cut   as   close   as   possible   to   the   services   to   be   installed   so   that   less   caulking   is
required.
It   is   also   advisable   to   investigate   all   approaches   that   potentially   remove   or   eliminate   penetrations.
Screwed   ceiling   light   fixtures,   for   example,   are   in   our   experience   often   specified   in   drawings   but   alternatives   that   eliminate   the   risk   of   air   leaks   through   screw   holes   are   available   and   are   preferable.
26

The   room   pressure   test   for   air   leaks   in   PC3   &   PC4   laboratories   is   200   Pascals   with   an   allowable   leakage   of   120   litres   per   minute.
The   approach   in   summary   is   therefore   two   fold:
1.
Minimise   penetrations   wherever   possible.
2.
Pay   close   attention   to   detail   for   any   required   penetrations.
The   examples   illustrated   on   the   following   pages   are   generally   those   associated   with   PC3   laboratory   environments   but   serve   to   highlight   a   variety   of   approaches   and   construction   techniques   suited   to   the   standards   required   generally   of   physical   containment   laboratories.
The   goal   of   a   fully   sealed   laboratory   is   why   penetrations   are   kept   to   a   minimum   and   where   required,   careful   attention   is   paid   to   sealing   these   penetrations.
27

Above:   A   typical   penetration   sleeve   for   hydraulic   services.
Below:   Thoroughly   coat   both   sides   of   the   wall   with   polyurethane   sealant   prior   to   installing   the   stainless   steel   sleeve.
28

Above   and   left:   Care   should   be   taken   with   penetrations   associated   with   gases   and   compressed   air.
Below:   Even   simple   installations   like   lab   coat   hooks   should   avoid   any   penetrations   created   by   screws   and   instead   form   part   of   solid   plates   which   are   fixed   to   walls   with   poly ‐ urethane   sealant   and   double   sided   tape.
29

Above:   Electrical   and   communication   systems   must   also   take   into   account   the   importance   of   sealing   the   penetration   into   the   PC   labo ‐ ratory.
Below   left:   Penetrations   details   for   hydraulic   services.
Below   right:   typical   penetration   sleeve.
30

Above:   Laboratory   gas   valves   and   regulators.
Note   the   sophisti ‐ cated   nature   of   the   fitting   which   involves   zero   wall   penetrations.
Below:   Fumigation   port   detail   for   a   PC3   Laboratory.
Ports   are   sand ‐ wiched   between   sealed   stainless   steel   plates   either   side   of   the   wall.
31

32

With   physical   containment   laboratories,   the   most   obvious   and   most   concerning   error   can   be   if   the   lab   does   not   hold   pressure   within   the   room   pressure   test ‐
ing   acceptance   criteria   stipulated   by   the   regulator.
This   can   result   from   design   or   delivery   errors,   the   wrong   choice   of   components   or   the   use   of   subcon ‐ tractors   or   suppliers   who   are   not   closely   supervised   by   experienced   containment   laboratory   builders.
It   can   be   very   difficult,   if   not   impossible   to   locate—   let   alone   repair—a   leak   if   a   lab   does   not   hold   pressure   within   the   acceptable   parameters    (the   permissible   leakage   cannot   exceed   2   litres   per   second   at   a   room
pressure   of   200pa).
In   fact,   Cockram   have   in   the   past   been   called   onto   projects   where   other   contractors   have   not   succeeded   with   sealing   and   certification   standards,   meaning   the   client   was   required   to   rebuild   new   containment   labs   using   the   correct   construction   techniques.
33


We   believe   we   have   built   more   PC   labs   in   Australia   than   any   other   builder.
Our   checklist   of   things   to   watch   for   to   avoid   mistakes   is   based   on   experience


 and   includes   the   following:

Choose   an   architect/design   team   who   have successfully   detailed   physical   containment
laboratories

Choose   a   builder   who   has   experience   in   the   successful   delivery   of    a   physical   containment   lab   facility
 Select   services   contractors   and   other   contrac ‐ tors   involved   with   the   laboratory   envelope   who   have   previously   worked   on   PC   facilities

Become   as   knowledgeable   as   you   can commissioning   and   what   is   involved
about
Ask
Be
a   lot   of   prepared seemingly
to   show
self your
evident   questions ignorance

Think   in   first   principles   about   what   the   sys ‐ tems   are   needing   to   achieve
Ensure   all   contractors   are   specifically   inducted   into   the   works   and   the   nature   of   the   PC   re ‐ quirements
Always   focus   on   detail,   detail,   detail.
34

If   you   need   some   advice   or   have   some   further   ques ‐ tions,   please   don’t   hesitate   to   contact   the   following   people.
Darren   Milne
Operations   Manager   Australia
0418   101   181   darren.milne@cockram.com
Michael   Read
New   South   Wales   State   Manager
0400   013   458
michael.read@cockram.com
Chris   Meade
Queensland   State   Manager
0439   037   017   chris.meade@cockram.com
Michael   Clemenger
Victorian   State   Manager
0407   535   672
michael.clemenger@cockram.com
Greg   Mithen
WA   State   Manager—Esslemont   Cockram
0417   644   647   greg.mithen@cockram.com
35

Completed   early   2012,   the   $43   million   Elizabeth   Macarthur   Agricultural
Biosecurity   (EMAI)   Upgrade   Project   designed   by   S2F   for   NSW   Public   Works
(Department   of   Finance   and   Services)   is   of   significant   importance   to   Australia   as   a   first   line   of   defence   to   a   catastrophic   disease   such   as   an   outbreak   of   foot   and   mouth   disease.
The   project   features   two   new   buildings   with   1,625   sqm   of
Physical   Containment   (PC)   or   Quarantine   Containment   (QC)   standards   PC2/QC2   laboratories,   and   775   sqm   of   PC3/QC3   laboratories,   plus   the   upgrade   of   existing   infrastructure   and   trade   waste   treatment   and   disposal   system,   as   well   as   the   refurbishment   of   six   (6)   existing   laboratory   buildings   totalling   600sqm   36
PC2   or   QC2   standard.

PC4.
Victorian   Infectious   Dis ‐ eases   Research   Laboratory.
Western   Health   Care   Network.
$4.4million.
1998.
PC3.
Goddard   Building   TERN   &
Insectary,   University   of   Queen ‐ sland.
$1.7
million.
2010.
PC3.
Faculty   of   Medicine   and
Health   Science,   University   of
Auckland,   NZ.
$2.3
million.
PC3   &   PC2.
Illawarra   Health   and   Medical   Research   Institute,
Wollongong.
$22   million.
2010.
37

PC3.
School   of   Veterinary   Sci ‐ ence.
JCU   Townsville.
$955,000.
2010.
PC3.
Institute   of   Health   &   Bio ‐ medical   Innovation.
QUT.
$813,000.
2010.
PC3   &   PC2;   QC3   &   QC2.
Eliza ‐ beth   Macarthur   Agricultural
Institute,   Biosecurity   Upgrade,
NSW.
$43   million.
2012.
PC3   &   PC2.
SmithKline
Beecham   Biologicals,   Shang ‐ hai,   China .
PC2.
Monash   Health   Research
Precinct.
$14.8
million.
2005.
38

PC2 .
Monash   University   STRIP.
$70.7million.
2009.
PC2.
Deakin   University   Shared
Laboratories.
$11.3
million.
2010.
PC2.
CSL   Building   4   HVB   –   R&D
Refurbishment.
$6.9
million.
2009.
PC2.
Blacktown   Clinical   School,
Education   and   Research   Cen ‐ tre.
$16   million.
2011.
PC2.
Cancer   Biology   Imaging
Facility,   Institute   for   Molecular
Bioscience   University   of
Queensland.
$545,000.
2009.
39

PC2   +   Cyclotron.
Centre   for
Advanced   Imaging,   University   of   Queensland.
$32.5
million.
2012.
PC2.
Victorian   Agribiosciences
Centre.
$16.5
million.
2005.
PC2   +   Class   100   &   Class
10,000.
Melbourne   Centre   for
Nanofabrication.
$13.5
million.
PC2.
Australian   Red   Cross
Blood   Service—Melbourne
Processing   Centre.
$57.1
mil ‐ lion.
2011.
40

Melbourne   Office
Ground   Floor
675   Victoria   Street
Abbotsford,   Vic   3067
Tel:   +61   3   8862   8888
Fax:   +61   3   8862   8900
Sydney   Office
Level   2,   500   Pacific   Highway
St   Leonards   NSW   2065
Tel:   +61   2   9818   6099
Fax:   +61   2   9818   6155
Brisbane   Office
Unit   2,   William   Jolly   Place
309   North   Quay
BRISBANE    QLD   4000
Tel:   07   3229   0288
Fax:   07   3229   5827
Perth   Office
57   McCoy   Street
Myaree   WA   6154
Tel:   +61   8   9330   2344
Shanghai   Office
Suite   14E,   Hua   Min   Empire   Plaza,
No.
728   Yan   An   (West)   Road,
Shanghai,   200050,
People’s   Republic   of   China
Tel:    +86   21   5238   3666
Fax:   +86   21   5239   7318
Tianjin   Office
A3 ‐ 705,   TEDA   New   Skyline,
No.
12   Nanhai   Road,
Tianjin,   300457,
People’s   Republic   of   China
Tel:    +86   22   6628   3452/53
Fax:   +86   22   6628   3451
Suzhou   Office
Room   1216,   Genway   Building,
No.
188   Wangdun   Road,
Suzhou   Industrial   Park,
Suzhou,   215123,
People’s   Republic   of   China
Tel:    +86   512   6660   7400
Fax:   +86   512   6660   7401
Guangzhou   Office
Room   2112,   China   Shine   Plaza,
No.
9   Linhe   (West)   Road,
Guangzhou,   510610,
People’s   Republic   of   China
Tel:    +86   20   3801   0245/46
Fax:   +86   20   8527   0717
India
India   Private   Limited
Level   4,   Dynasty   Business   Park,
Andheri   –   Kural   Road.
Andheri   (East)
Mumbai   –   400   059
Telephone:   +91   22   4030   9118
Kalamazoo  ‐  Michigan
8175   Creekside   Drive
Suite   260,   Portage,   MI   49024
Tel:   +269   321   5068
Fax:   +269   321   5069
Puerto   Rico   Office
Metro   Office   Park
Street   1,   Building   11,   Suite   106
Guaynabo   PR   00968  ‐  1705
Tel:   +1   787   273   2277
Fax:   +1   787   273   2279
41

Australian   Red   Cross   Blood   Service,   Melbourne   Processing   Centre,   completed   in
2011   by   Cockram   Construction.
The   ARCBS   facility   included   extensive
42 laboratory   areas.