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EIPICO BIOLOGICALS & BIOSIMILARS MANUFACTURING FACILITY (EIPICO 3)
ROWAD Modern Engineering Case Study

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Project Card
Project information
Location:n10th of Ramadan City - 1st Industrial Zone B1, EgyptnClient:nEgyptian International Pharmaceutical Industries Co. (EIPICO)nConsultant:nCosmos-E Engineers & ConsultantsnSector:nPharmaceutical, Strategic national project; first modular buildings manufacturing facility for biologics/biosimilars in the Middle EastnTechnology Providersn:nPharmadule

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1. PROJECT OVERVIEW
is proud to deliver the EIPICO Biologicals & Biosimilars Manufacturing Facility (EIPICO 3), located in the 10th of Ramadan City - 1st Industrial Zone B1, encompassing a total land area of 10,344.64mu00b2. This project significantly advances Egyptu2019s pharmaceutical self-reliance and aims to expedite access to high value therapies across the region.

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, a highly specialized international supplier, as part of the ROWAD scope of work.
ROWAD Modern Engineeringu2019s turnkey scope encompasses the following:nArchitectural Works:nExecution of the building's architectural elements.nStructural Works:nImplementation of all structural systems ensuring stability and durability.nMechanical, Electrical, and Plumbing (MEP):nInstallation of all MEP systems essential for facility operations.nUtilities:nProvision of necessary utility connections and infrastructure.nExternal Works:nDevelopment of the surrounding site, including landscaping and access roads.nClean Room:nThis section has been subcontracted tonLinelinknProduction Area, including Cold Store Area:n(Fixed Rack & Mobile Rack with temperature control (2 - 8u00b0C): This has been subcontracted to PSI, another specialized international supplier, under the ROWAD scope of work.nFull Project Controls:nComprehensive management and oversight to ensure project timelines and quality standards are met.nIn addition to the above, ROWADu2019s scope includes the foundation, pedestals, and all tie-ins for MEP systems related to the Modular Building provided bynPharmadulen.nBIM Standard Applied ISO 19650nBIM Level of Detail LOD 350 u2192 LOD 400 u2192 LOD 500 (phased progression through construction and as-built closeout)nBIM Activities Shop drawings for all trades; Architectural & MEP fabrication drawings; QS extraction from models; Coordination & clash reports; Equipment-to-structure coordination; As-Built models for FM usen2. SCOPE OF WORK
- ROWAD Modern Engineeringu2019s turnkey scope encompasses the following:
- Architectural Works:
- Execution of the building's architectural elements.
- Structural Works:
- Implementation of all structural systems ensuring stability and durability.
- Mechanical, Electrical, and Plumbing (MEP):
- Installation of all MEP systems essential for facility operations.
- Utilities:

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BUILDING PROGRAM SUMMARY (BUA)
BUILDINGnFLOORSnBUA (Mu00b2)nAdmin BuildingnG+2n1,868nWarehouse BuildingnG+2n6,450nModular BuildingnG+1n4,912nTransformer BuildingnGn117nBoiler, Chiller Area and Power StationnG+1n704nBUILDINGnFLOORSnBUA (Mu00b2)nWorkers Building, Fire Tank andnDomestic TanknG+1n389nSolvent and Hazardous StoragenGn51.6nEntry Guard RoomnGn16.72nExit Guard RoomnGn16.72nNatural GasnGn26.8nFuel TanknGn19.6nBio-Waste TanknGn129.6
- BUILDING
- FLOORS
- BUA (Mu00b2)
- Admin Building
- 1,868
- Warehouse Building

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3. KEY QUANTITATIVE HIGHLIGHTS
1. EARTHWORKS (CUBIC METERS)nNO.nEARTHWORKSnQTY. M3nExcavationn13,876.02nFillingn6,816.74n2. PILING WORKS (LINEAR METERS)nNO.nPILING WORKSnQTY. MnPilingn3. CONCRETE WORKS (CUBIC METERS)nNO.nCONCRETE WORKSnQTY. M3nPlain Concreten1,865.13nReinforced Concreten8,978.20n4. BUILDING WORKS (SQUARE METERS)nNO.nBUILDINGS WORKSnQTY. M2nSolid cement blocks masonry unitsn11,720.66n5. STEEL STRUCTURE ERECTION (TONS)nNO.nSTEEL STRUCTUREnQTY. TONnPipe and electrical cables RacksnSupply and erection base plates for fixing the prefabricated modular buildingn10.38nMetal Grating Stair with steel Shedn3.5
- 1. EARTHWORKS (CUBIC METERS)
- EARTHWORKS
- QTY. M3
- Excavation
- 13,876.02
- Filling
- 6,816.74

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6. EQUIPMENT ERECTION (TONS)
NO.nEQUIPMENTu2019SnQTY.nWEIGHT (KG) EACHnWater cooled chillersn7100nAir cooled chillersn3700nCooling towersn11750nWater cooled Pumpsn1300nAir cooled Pumpsn1250nCooling towers Pumpsn1500nAir compressorsn1650nAir dryern500nAir vesseln700nSteam boilersn20000nDeaeratorn7000nHear misern1000nAHUs at B01n3000nAHUs at B02n20000nElec. Firefighting pumpsn3750nDiesel Firefighting pumpsn3550nBooster pump setn500nCirculating pumpsn200nGeneratorsn6700nNO.nEQUIPMENTu2019SnQTY.nWEIGHT (KG) EACHnTransformersn1500nMVSGn1500nMDBs/EMDBsn1000
- EQUIPMENTu2019S
- QTY.
- WEIGHT (KG) EACH
- Water cooled chillers
- 7100
- Air cooled chillers
- 3700

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7. PIPING ERECTION (INCH/METER)
NO.nDIAMETERnCHILLED PIPES (M)nFIRE PIPES (M)nDiameter 20mmnDiameter 25mmn340n2476nDiameter 32mmn295n324nDiameter 40mmn591nDiameter 50mmn305n460nDiameter 65mmn262n388nDiameter 80mmn375n186nDiameter 100mmn503n243nDiameter 150mmn218n261nDiameter 200mmn245n116nDiameter 250mmnDiameter 300mmn255n8. ELECTRICAL WORKS (KM OF CABLES)nNO.nCABLE CROSS SECTION AREAnMn(3X240+120) CU/MICA/XLPE/LSZHn1848n(3X185+95 mm2) CU/MICA/XLPE/LSZHn150n(3X120+1X70) CU/MICA/XLPE/LSZOHn(3X150+70mm2) CU/MICA/XLPE/LSZH
- DIAMETER
- CHILLED PIPES (M)
- FIRE PIPES (M)
- Diameter 20mm
- Diameter 25mm
- 2476

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NO.
CABLE CROSS SECTION AREAnMn(4X50mm2) CU/MICA/XLPE/LSZHn(3X50+25mm2) CU/MICA/XLPE/LSZOHn(4X25mm2) CU/MICA/XLPE/LSZHn130n(4X10mm2) CU/MICA/XLPE/LSZHn129n(4X35mm2) CU/MICA/XLPE/LSZHn105n(2X6) CU/MICA/XLPE/LSZOHn(3X300+150) CU/XLPE/PVCn1050n(3X240+120) CU/XLPE/PVCn1311n(3CX150+70) CU/XLPE/PVCn155n(3X70+35) CU/XLPE/PVCn200n(3X95+50mm2) CU/XLPE/PVCn208n(3X50+25mm2) CU/XLPE/PVCn(4x35mm2) CU/XLPE/PVCn250n4X25CU/XLPE/PVCn220n3X25+16 CU/XLPE/PVCn4X16 CU/XLPE/PVCn4X10 CU/XLPE/PVCn785n4X6 CU/XLPE/PVCn(3X300+150) CU/PVC/PVCn(4X95mm2) CU/PVC/PVCn145
- CABLE CROSS SECTION AREA
- (4X50mm2) CU/MICA/XLPE/LSZH
- (3X50+25mm2) CU/MICA/XLPE/LSZOH
- (4X25mm2) CU/MICA/XLPE/LSZH
- (4X10mm2) CU/MICA/XLPE/LSZH

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NO.
CABLE CROSS SECTION AREAnMn(4X35mm2) CU/PVC/PVCn(4X25mm2) CU/PVC/PVCn4X10 CU/PVC/PVCn4X6 CU/PVC/PVCn816n3X6 CU/PVC/PVCn1850n3X4 CU/PVC/PVCn20000n3X3 CU/PVC/PVCn20000n150 CU/PVC/PVCn395n120 CU/PVC/PVCn1198n95 CU/PVC/PVCn70 CU/PVC/PVCn169n50 CU/PVC/PVCn353n35 CU/PVC/PVCn246n25 CU/PVC/PVCn130n16 CU/PVC/PVCn908n10 CU/PVC/PVCn985n6 CU/PVC/PVCn953
- CABLE CROSS SECTION AREA
- (4X35mm2) CU/PVC/PVC
- (4X25mm2) CU/PVC/PVC
- 4X10 CU/PVC/PVC
- 4X6 CU/PVC/PVC
- 3X6 CU/PVC/PVC

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9. ELECTRICAL WORKS (KM OF CONDUITS & CABLE TRAYS, TRUNKS)
NO.nITEMnQUANTITYnu00beu201d EMT conduitsn15000n20 mm UPVC conduitsn10000n25 mm UPVC conduitsn12000nCable trays 90x10 CMnCable trays 60x10 CMn312nCable trays 50x10 CMnCable trays 40x10 CMnCable trays 30x10 CMn330nCable trays 20x10 CMn560nCable trays 10x10 CMn800nCable trunk 20x10 CMn500nCable trunk 10x10 CMn350
- ITEM
- QUANTITY
- u00beu201d EMT conduits
- 15000
- 20 mm UPVC conduits
- 10000
- 25 mm UPVC conduits

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10. ELECTRICAL WORKS (KM OF UPVC CONDUITS DUCT BANK).
NO.nITEMnQUANTITYn4xu00d850 mm UPVC conduit.n119n2xu00d850 mm UPVC conduit.n113n9xu00d8110mm UPVC conduit road crossing for power cable.n2xu00d8110mm UPVC conduit road crossing for street lighting cable.n4xu00d850mm UPVC conduit road crossing for fiber cable.n160n11. INSTRUMENTATION WORKS (KM OF CABLES).nNO.nITEMnQUANTITYn(1x12) Multimode fiber optic cable.n1100n(1x4) Multimode fiber optic cable for Fire Alarm system loop.n600nCAT 6 cable.n35075nPublic address Cable 2x2.5 mm.n700nFire alarm cable 2x1.5 mm.n12000nFire alarm cable 2x2.5 mm.n8000nBMS cable 2x1 mm.n26510nBMS cable 3x1 mm.n17103nBMS cable 4x1 mm.n34350nBMS cable 6x1 mm.n900
- ITEM
- QUANTITY
- 4xu00d850 mm UPVC conduit.
- 2xu00d850 mm UPVC conduit.
- 9xu00d8110mm UPVC conduit road crossing for power cable.

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12. 10.PIPES INSULATION WORKS (METER)
NO.nDIAMETERnCHILLED PIPES INSULATION (M)nDiameter 20mmnDiameter 25mmn340nDiameter 32mmn295nDiameter 40mmnDiameter 50mmn305nNO.nDIAMETERnCHILLED PIPES INSULATION (M)nDiameter 65mmn262nDiameter 80mmn375nDiameter 100mmn503nDiameter 150mmn218nDiameter 200mmn245nDiameter 250mmnDiameter 300mmn255n13. DUCT INSULATION WORKS (SQUARE METER)nNO.nDIAMETERnDUCT INSULATION (M2)nFiber Glass, Thickness 25mm for Indoor duct, and 50mm for outdoor duct, 24 Kg/m3 densityn12000
- DIAMETER
- CHILLED PIPES INSULATION (M)
- Diameter 20mm
- Diameter 25mm
- Diameter 32mm

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3. COMMERCIAL ASPECTS AND WORKFORCE DEPLOYMENT
14. PAINTING WORKS (SQUARE METER)nNO.nPAINTING WORKSnQTY. M2nInternal Paintingn16,482.00nExterior Paintingn4,747.25nAmount of the contractn36,348,949 USDnTotal spent direct man-hours (Mhrs)n3,690,479nDirect workers at peak (Number of Direct Workers)n440n% subcontractedn90%,n4. PROJECT DURATIONnProject Start daten18 Sep 2022nProject Completion daten30 Oct 2025
- 14. PAINTING WORKS (SQUARE METER)
- PAINTING WORKS
- QTY. M2
- Internal Painting
- 16,482.00
- Exterior Painting
- 4,747.25

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5. ENGINEERING CHALLENGES AND SOLUATION
Tight Delivery Program:nThis challenge was mitigated through parallel off-site fabrication combined with on-site foundation and utilities works, ensuring timely progress without compromising quality.nRegulatory/GMP Interface Management:nEarly engagement with stakeholders, coupled with robust documentation control and the use of mockups, facilitated smooth compliance with regulatory requirements and Good Manufacturing Practices (GMP).nHeavy Lifts and Constrained Lay-Down Areas:nEngineered lifting studies were conducted to ensure safe operations, while just-in-time logistics were implemented to optimize material handling and site efficiency.

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6. ACHIEVEMENTS
This project showcased the full breadth of ROWADu2019s multidisciplinary expertise, particularly in the following areas:nIntegrated Civil and MEP Delivery for GMP Facilities:nEnsuring seamless coordination between civil and mechanical, electrical, and plumbing systems tailored to GMP standards.nBIM Coordination and Clash-Free Modular Installations:nUtilization of Building Information Modeling (BIM) to enhance project coordination and eliminate conflicts during the installation of modular components.nClean Utilities and HVAC for Controlled Environments:nImplementation of advanced clean utility systems and HVAC solutions designed to maintain the required environmental conditions for sensitive manufacturing processes.nFast-Track, High-HSE Industrial Execution:nCommitment to high health, safety, and environmental (HSE) standards while adhering to accelerated project timelines.
- This project showcased the full breadth of ROWADu2019s multidisciplinary expertise, particularly in the following areas:
- Integrated Civil and MEP Delivery for GMP Facilities:
- Ensuring seamless coordination between civil and mechanical, electrical, and plumbing systems tailored to GMP standards.
- BIM Coordination and Clash-Free Modular Installations:
- Utilization of Building Information Modeling (BIM) to enhance project coordination and eliminate conflicts during the installation of modular components.
- Clean Utilities and HVAC for Controlled Environments:
- Implementation of advanced clean utility systems and HVAC solutions designed to maintain the required environmental conditions for sensitive manufacturing processes.
- Fast-Track, High-HSE Industrial Execution:

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7. CONCLUSION
These achievements not only underscore ROWADu2019s technical capabilities but also reaffirm its commitment to delivering high-quality, safe, hygienic, and sustainable solutions in the (Pharmaceutical) sector.n8. STRATEGIC IMPACTnThe EIPICO 3 facility is a strategic national asset that enables local manufacturing of advanced biologics and biosimilars. This initiative not only bolsters Egyptu2019s healthcare resilience but also enhances the country's export potential, contributing to a stronger economy and improved health outcomes.

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Slide 18

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Thank You
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