Kingston Building was engaged under an Early Contractor Involvement arrangement to assist Whiteley to repurpose their Tomago facility into a world-class manufacturing plant for hospital-grade hand sanitiser and other therapeutic goods.

The project began with the demolition of the existing office and the internal strip-out of the warehouse. A new 2-storey office building was constructed, comprising multiple offices, an open-plan area for 20 workstations, a boardroom and a hot desk/breakout area. The office also features a timber and glass staircase, passenger lift, 2 kitchens, a comms room and amenities.

Within the existing industrial structure, a new 2-storey manufacturing facility was built to meet TGA standards. This includes 4 laboratories, a bunded mixing tank area, filling stations, clean equipment storage areas, a dispensary, and a pallet wrapping zone.

The facility also includes a 1,000m² warehouse with pallet racking, and an internal mezzanine plantroom for mechanical systems.

Several challenges were addressed, including site-specific hazard studies to ensure mechanical zoning and pressurisation prevented hazardous gas mixing. Anti-static finishes, including specialised flooring and SteriGuard paint, were essential to eliminate spark risks.

Construction techniques were customised to meet strict compliance standards. Bondor Panels were used instead of plasterboard for their sterile, dust-resistant properties and quick installation. Precise detailing eliminated dust-trapping ledges, and a rotating handrail system ensured safe lifting of mechanical plant to the mezzanine. A 250kg, two-hour fi re-rated viewing window was installed using winches, avoiding the need for wall-washing sprinklers. HEPA filters were integrated to maintain cleanroom air quality and protect both products and workers.