UK’s first CAR-T cell manufacturing facility
Autolus Therapeutics, a trailblazing biopharmaceutical company specialising in next-generation T-Cell therapies, had initially planned to build the facility in the US. However, they chose the UK after Merit proposed an accelerated solution, which enabled the project to be completed in a record 17 months, with just 12 months onsite.
The facility was built using Merit’s FLEXI POD® product, which integrates traditional construction methods with Modern Methods of Construction (MMC). This innovative approach combines a conventional shell and core with offsite-manufactured fit-out elements, including PODs and Pre-Assembled Modules (PAMs). The facility also needed to meet rigorous joint MHRA and FDA licensing requirements. By completing the project three years faster than the industry standard, the new facility will enable Autolus to produce 6,000 cancer treatments by 2025, accelerating the delivery of life-saving therapies.
Delivery of a cutting-edge, four-storey CAR-T cell and gene therapy manufacturing facility.
7,500m² utilising Merit’s FLEXI POD® solution.
Implementation of Merit’s pioneering digital twin technology, a first for the company.
Facility includes Grade C cleanrooms, laboratories, offices and warehouse space.
Riser-free layout ensures future expansion and adaptability.
Urban construction: The site’s tight inner-city location, limited space and close proximity to a dual carriageway and residential apartments posed significant challenges. Merit’s factory-manufactured fit-out design addressed these constraints and reduced onsite labour by an impressive 80% compared to conventional methods.
Achieved 76% Pre-Manufactured Value (PMV): This indicates a high degree of offsite manufacturing, significantly reducing onsite construction time and labour.
Delivered the £60m facility to budget: The project was completed within the allocated budget, despite challenges such as post-COVID restrictions and material shortages.
Completed Phase 1 handover of Grade C cleanrooms in 17 months: The initial phase, including the cleanrooms, was delivered ahead of the overall project schedule, showcasing a remarkable acceleration in construction.
Total project duration of 22 months: The entire project was completed in 22 months, three years faster than the industry standard for similar facilities.
Certified as Zero Scope 1 Carbon Enabled, BREEAM Excellent and EPC-A Rated: The facility meets high environmental standards, with certifications reflecting its sustainability and energy efficiency.
Chief Technical Officer
Autolus Therapeutics
“The entire project team, including Autolus, Merit and Reef Group has successfully kept this project on track despite challenging timelines, the COVID pandemic, and supply chain constraints. Their efforts have enabled us to transition seamlessly into the next phase of growth for Autolus. ”
