5 Reasons to Design with Modular and Off-Site Construction: Building a Greener Future

Building on the resounding success of the LEED Platinum-certified Sartorius ECO I facility, PIERI Architects spearheaded the design of a transformative 40-acre expansion to Sartorius Stedim Biotech’s manufacturing campus. This master-planned project supports Sartorius’ mission to deliver world-class biopharmaceutical technologies, adding significant capacity and operational functionality to their Yauco, Puerto Rico facility. A Visionary Partnership The project, executed under a fast-track Construction Manager at Risk (CMAR) delivery method, was a collaborative endeavor involving PIERI Architects, CIC Construction, and Caribbean Project Management. Seamless coordination and communication were paramount in this high-stakes environment, where balancing time, budget, and quality were critical. Leveraging our integrative design process, PIERI Architects facilitated continuous alignment between Sartorius’ local team in Puerto Rico and their global counterparts in Germany and France. This approach ensured that the facility met both operational and cultural benchmarks, while maintaining the technical rigor required for a pioneering biopharma manufacturing campus. Expanding Capabilities The 355,000-square-foot expansion includes: 230,000 square feet dedicated to Fluid Management Technologies (FMT), featuring ISO 7 and ISO 5 Bio-Safe cleanroom manufacturing spaces, high-density warehousing, administrative offices, quality control laboratories, and employee amenities. 85,000 square feet** for Filtration Membrane and Casting manufacturing. Advanced Central Utility Plant facility and site infrastructure distribution. Designed to serve Sartorius’ North American market, the facility provides cutting-edge spaces for the production of filtration and fluid management technologies. In addition to manufacturing excellence, the project delivered substantial economic benefits, generating 450 construction jobs and 550 long-term positions in southwestern Puerto Rico. Excellence in Sustainable Design Sustainability and resilience were central to the project. By integrating innovative strategies and adhering to rigorous standards, PIERI Architects ensured the campus exemplifies environmental stewardship and operational efficiency. Highlights include: - Low-impact site development: Habitat restoration, drought-tolerant native landscaping, significant stormwater runoff reduction, heat island mitigation, and dark-skies-compliant lighting. - Water conservation: A 67% reduction in potable water consumption through advanced water management strategies. - Energy optimization: A 35% improvement in energy performance compared to ASHRAE 90.1 2016 standards. - Construction innovations: Modular assemblies and off-site construction methods minimized waste and expedited the build process, while diverting 85% of construction waste from landfills. - Healthy environments: Implementation of an Indoor Air Quality Management Plan during construction and use of low-emitting materials for all finishes. - Robust commissioning: A coordinated validation and commissioning process ensured all systems met design performance goals. The facility is designed to achieve LEED-NC 2009 Gold certification, underscoring Sartorius’ commitment to sustainable excellence. Key Project Data Sustainability Features - Low-impact design with habitat restoration and stormwater management. - 67% reduction in potable water consumption. - 35% energy savings over ASHRAE 90.1 2015 standards. - Modular and off-site construction reduced waste and disruption. - 85% construction waste diversion. - Dark-skies compliant site lighting. - Healthy indoor environments through low-emitting materials. Performance Metrics - New Trees Planted: 1,700 - Water Savings: 67% potable water reduction - Energy Use: 35 kWh/sqft/year - Construction Waste Diverted: 85% - LEED Rating: Gold - Total Project Cost: \$84.5 million - Completion: July 2019 Project Team - Owner: Sartorius Stedim Biotech - Architect: PIERI Architects - General Contractor: CIC Construction, Inc. - Project Manager: Caribbean Project Management - MEP Contractor: BLDM - Civil Engineer: DG3 Engineers - Mechanical Engineer: Jose Luis Marrero, PE - Structural Engineer: Fernando Cortes, PE - Electrical Engineer: Daniel Rosell Suarez, PE - Landscape Contractor: Defensores de la Cuenca Key Project Collaborators - Rainer Lehman, CFO Sartorius Group: Provided strategic leadership emphasizing the importance of the facility. - Uwe Becker, Sartorius International Development Manager: Ensured alignment with global sustainability and operational goals. - Marcos Lopez, General Manager of Sartorius Stedim Filters Puerto Rico: Offered invaluable insights into local operational requirements. - Efrain Rodriguez, FMT Operations Vice President: Supported technical and operational alignment of the cleanroom facility. - Dr. Carsten Funk, Membrane and Casting Operations Vice President: Supported technical and operational alignment of the Membrane Casting operations and Distillation Plant facility. - Ivan Cruz, Sartorius Facilities Project Manager: Served as Owner’s representative, providing day-to-day support, communication, and coordination. - Michael Pabon, Project Lead for CIC Construction: Promoted constructability and fiscal discipline in collaboration with the design team. - Miguel Mercado, Project Manager from Caribbean Project Management: Facilitated communication and coordination between all parties. "The measure of a project's success is how well the client's needs are integrated into the design. The Sartorius Campus Expansion achieved this through a high level of communication, cooperation, and teamwork between Sartorius, PIERI Architects, and the Construction team." Efrain Rodriguez, FMT Operations Vice President, Sartorius Biotech

Vincent Pieri • May 11, 2025

In today's evolving architectural landscape, the imperative to build sustainably is paramount. As architects specializing in ecologically principled "green" design, we're guided by a core principle: sustainability. We define this, as architect Steve Mouzon eloquently put it, as "keeping things going in a healthy manner, long into an uncertain future." This is crucial given the increasing variables affecting our planet. We explore innovative strategies to minimize our environmental footprint and maximize efficiency, with modular and off-site construction leading the way.

What is Modular Construction?

Modular construction involves designing and fabricating building components in a controlled off-site environment, then transporting and assembling them on-site. This process relies on a nested 3-dimensional modular framework, ensuring all building elements—from structural components to finishes—are integrated. By considering the span, height, and placement of elements, we create cohesive and efficient building systems.

The concept of modularity evolved from traditional craftwork's standardized units to today's industrialized systems. Historically, craftspeople used consistent dimensions for efficiency. The industrial revolution expanded this, leading to standardized materials like bricks, steel, metal framing, and plywood. Architects leverage this modularity, recognizing the dimensional consistency that facilitates systematic design.

Modular design and construction occur both off-site and on-site through detailed planning. For example, steel components are fabricated off-site, while metal framing can be assembled off-site or on-site. Concrete construction also employs modularity, with off-site precast elements and on-site "tilt-up" construction.

By utilizing these inherent modular dimensions, designers create a hierarchical dimensioning system that optimizes material use and reduces waste and construction time. This integrated process ensures all elements work seamlessly.

Here are five compelling reasons to consider modular and off-site construction:

1. Reduced Construction Waste:

Off-site fabrication in controlled settings minimizes waste through precise material use. Excess materials are easily recycled, contributing to a circular economy. The controlled environment also reduces weather-related damage.

2. Enhanced Quality Control and Precision:

Factory production allows for rigorous quality control, ensuring consistent quality and minimizing errors. This precision improves building performance, reduces energy consumption, and enhances durability.

3. Faster Construction Times and Reduced On-Site Disruption:

Simultaneous off-site fabrication and site preparation significantly shorten timelines and reduce project overhead. Reduced on-site time minimizes community disruption and environmental impact, especially in urban areas.

4. Improved Energy Efficiency and Sustainability:

Modular construction enables the integration of advanced energy-efficient technologies, such as high-performance insulation and renewable energy systems. Controlled factory environments ensure optimal performance and minimize energy loss.

5. Cost-Effectiveness and Predictability:

While initial costs may seem higher, long-term savings are substantial due to reduced construction time, waste, and improved quality control. Off-site fabrication provides cost predictability, aiding budget management.

Embracing the Future of Green Building

Modular and off-site construction represents a paradigm shift. By embracing these techniques, we create sustainable, efficient, and resilient buildings. As architects dedicated to ecologically principled design, we champion these approaches for a greener future, ensuring we are "keeping things going in a healthy manner, long into an uncertain future."