Negative Pressure Demolition in an Active Pharmaceutical R&D Laboratory

R. Baker & Son had the unique opportunity to return to a pharmaceutical R&D laboratory project we had successfully completed years earlier, where our riggers and millwrights originally installed nine downflow booths. The client needed to reclaim the valuable real estate occupied by these booths to accommodate their expanding laboratory and process requirements.

Strict Safety Requirements for Occupied Laboratory Demolition
Our client established several critical requirements as we prepared to work within their active, occupied lab building. First, we needed to safely isolate the downflow booth area to prevent any dust or contaminants from escaping into surrounding laboratories. Second, they requested that we carefully dismantle the downflow booths and preserve them for reconditioning and future use at another facility. Finally, critical fiber optic cabling running above the work area required complete protection throughout the project.

Comprehensive Safety and Decontamination Protocol
Working with R. Baker's approved safety and demolition plan, the owner removed all HEPA filtration systems from the downflow booths and had the entire area professionally decontaminated before any dismantling or demolition activities began. The electrical and mechanical teams performed all required lockout/tagout procedures to ensure everyone’s safety.

Creating Negative Pressure Conditions
In collaboration with the controls contractor, we developed a strategic plan to shut down the supply air system while utilizing the downflow booth's main exhaust system to create negative pressure conditions within the work area. We installed two layers of MERV 8 filter fabric over the main exhaust to maintain clean ductwork throughout the project. Two Magnehelic gauges were strategically placed to provide continuous verification to the client that the workspace maintained negative pressure relative to the exterior laboratories at all times.

Protecting Critical Infrastructure
The IT department worked closely with R. Baker teams to clearly identify existing fiber optic conduits using fluorescent paint and colored ribbons, ensuring complete protection of these vital communication systems. After all electrical systems and sprinkler lines were properly isolated and secured, R. Baker deployed parallel work crews. One team carefully dismantled the existing downflow booths while another performed selective demolition by removing corridor ceilings, lights, sprinkler systems, and ductwork before progressing to walls and flooring.

Preservation and Material Management
We meticulously dismantled, bundled, and individually packaged all nine downflow booths for refurbishment and future installation at another facility. As ductwork removal progressed, our team continuously monitored and replaced the MERV 8 exhaust filtration in both the workspace and exhaust fan system. All contained demolition materials were removed during off-hours via a freight elevator located just outside the work area to minimize disruption to laboratory operations.

Overcoming Project Challenges
One particular challenge involved removing the epoxy floor coating throughout the space. To maintain our project schedule, we brought in additional ride-on floor scrapers to expedite this labor-intensive process. We also removed several large Mettler Toledo floor scales, filling the resulting voids with rebar and concrete for structural integrity.

Daily housekeeping protocols included comprehensive broom sweeping using dust-control sweeping compound, along with HEPA vacuuming of all nooks and crannies to maintain the cleanest possible environment.

Minimizing Disruption to Active Research
To absolutely minimize disruption to surrounding active laboratories, our demolition teams worked every other Saturday to complete noisy demolition activities and any work involving significant vibration during times when the building had minimal occupancy.

Project Success and Client Satisfaction
Upon demolition completion and final punchlist review, the client expressed high satisfaction with the results, confirming that new construction could begin on schedule as planned. They were particularly impressed with the effectiveness of our negative pressure exhaust system - so much so that they maintained it throughout the subsequent new construction phase to preserve a clean workspace and protect the overall building environment.

R. Baker & Son - Rigging & Demoliton Contractors
190 Boundary Road
Marlboro, NJ 07746
732-222-3553

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