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Project Spotlight
BPI Labs
Pharmaceutical Manufacturing Facility
BPI Labs—an industry leader in pharmaceutical manufacturing—partnered with Western Steel Buildings to create a precision-engineered steel facility designed to support regulated production environments and high-efficiency workflows. Western Steel delivered a 14,900 sq. ft. multi-span pre-engineered building that leverages strategically placed interior columns to optimize structural efficiency across a wide footprint.
The building incorporates a custom insulation package and extensive daylighting features, including (48) 3′ × 5′-4″ light transmitting panels, enhancing interior visibility and contributing to a more efficient manufacturing environment. Engineered for durability, thermal performance, and long-term operational reliability, this facility supports BPI Labs’ commitment to innovation, quality, and compliance.
Project Scope & Scale
- Use: Pharmaceutical manufacturing facility
- Building Size: 14,900 sq. ft.
- Dimensions: 108′ × 138′
- Frame Type: Tapered, multi-span interior column design
- Roof Type: Gable, 2:12 slope
- Roof System: Standing Seam, 24-gauge
- Wall System: PBR panel system, 26-gauge
- Light Transmitting Panels: (48) 3′ × 5′-4″ panels per customer specifications
- Insulation:
– Roof: R-30 multi-layer (6″ R-19 + 3.5″ R-11) with vapor barrier
– Walls: R-19 blanket with vapor barrier
Key Challenges
- Designing a multi-span structure capable of supporting pharmaceutical production processes.
- Delivering high insulation performance suitable for controlled environments.
- Integrating 48 daylight panels while maintaining structural and energy efficiency.
- Providing consistent interior clearances across a wide manufacturing footprint.
Solution / Approach
- Engineered a multi-span frame system with a centered row of columns to optimize load distribution and structural efficiency.
- Specified a high-performance insulation assembly to support temperature stability and regulatory compliance.
- Added (48) strategically placed light transmitting panels to enhance natural lighting and reduce daytime energy usage.
- Utilized PBR wall panels and standing seam roof panels for durability, cleanability, and long-term performance.
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Unique Features
- Multi-span column layout designed specifically for manufacturing flow and equipment placement.
- High-efficiency insulation package supporting pharmaceutical-grade climate control.
- Extensive daylighting through 48 translucent panels.
- Durable, low-maintenance PBR wall system.
- Standing seam roof with superior weather resistance and longevity.
Building Specifications
- Width: 108′
- Length: 138′
- Square Footage: 14,900 sq. ft.
- Eave Height (FSW/BSW): 23′
- Roof Slope: 2:12
- Roof Type: Gable
- Roof Panels: Standing Seam, 24-gauge
- Wall Panels: PBR, 26-gauge
- Frame Type: Tapered multi-span frame
Sustainability / Compliance
- Multi-layer insulation supports energy efficiency and controlled-climate production.
- Translucent daylight panels reduce daytime lighting demand.
- Steel building systems offer long-term lifecycle performance.
- Structural and envelope design aligned with IBC 2018 and relevant pharmaceutical manufacturing standards.
Results & Benefits
- Delivered a durable, energy-efficient manufacturing facility built for precision operations.
- Improved workflow through a multi-span structure optimized for equipment and process layouts.
- Enhanced interior lighting and comfort with extensive daylight panels.
- Provided a low-maintenance, high-performance steel building supporting long-term pharmaceutical production.
Build a high-performance manufacturing facility engineered for precision, efficiency, and long-term reliability.
Western Steel Buildings is SolutionCentric.®
We started Western Steel to create solutions to the major challenges of our industry. Western Steel Buildings is SolutionCentric.® Client problem solving is at the core of what we do. Every day, our team looks for the opportunity to proactively help projects go right.
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