Phased Expansion Shapes a cGMP-Ready Laboratory
Solvias’ new Research Triangle Park Center of Excellence was designed from the ground up to be cGMP-compliant and adaptable, delivering advanced analytical services to meet growing US demand. Image: Courtesy of Solvias
When Solvias, a global chemistry, manufacturing, and controls (CMC) analytics company, decided to expand its US footprint, the team knew the stakes were high. The demand for advanced analytical services—particularly for biologics and novel modalities such as adeno-associated virus (AAV), mRNA, monoclonal antibodies, and cell therapies—was growing rapidly. The company’s European labs had long supported these programs across the product lifecycle, but customers were asking for the same level of expertise closer to home.
The solution was a Center of Excellence in Research Triangle Park (RTP) in North Carolina, designed from the ground up to be both cGMP-compliant and adaptable to an evolving market. In just over a year, Solvias transformed shell space into an operational laboratory, achieving cGMP readiness while laying the groundwork for future growth.
The project team included JLL PDS, project and development services (project management); SCB (Soloman Cordwell Buenz) (architect); WB Engineers (mechanical/electrical/plumbing engineer); RFD (Research Facilities Design) (lab planner); McAdams (civil engineer); Barringer Construction (general contractor); Nycom (lab FF&E); JLL Furniture Solutions & Interior Elements (office furniture); JLL PDS (sustainability/LEED consultant); JLL PDS (commissioning agent); and Bennet Pless (structural).
A phased approach to expansion
Rather than building to full capacity immediately, Solvias pursued a phased expansion strategy. Phase 1 began in June 2024 and wrapped up six months later, delivering 20,000 square feet focused on cell-based bioassays and physical chemistry. This initial footprint allowed Solvias to service clients quickly while validating workflows and demand.
Phase 2, completed in July 2025, added another 30,000 square feet and significantly broadened the lab’s capabilities. The expanded space supports molecular biology—including Next Generation Sequencing (NGS)—as well as dedicated virology and lentivirus suites, and expanded biophysical characterization platforms. These additions were deliberately chosen to align with customer needs and emerging therapeutic trends.
As Christopher Hepler, site head at Solvias, explains, “Phased expansion was chosen with risk mitigation and customer focus in mind. Starting with a smaller, focused build allowed Solvias to validate market demand and operational efficiency while also enabling ongoing collaboration with US-based clients, allowing the facility to evolve in alignment with real-time feedback and emerging needs”.
Designing for flexibility and future growth
From the outset, adaptability was a guiding principle in the RTP project. The team employed modular layouts to enable reconfigurable lab spaces, ensuring the facility can pivot as new modalities emerge or workflows change.
Digital infrastructure was another area of emphasis. Advanced data management systems were embedded into the design to handle growing data volumes and regulatory requirements. These systems not only streamline compliance but are scalable to meet future demands. Automation was integrated early as well, creating the capacity to adjust quickly to new assay formats or testing protocols without significant downtime.
Dedicated suites for specialized modalities—such as lentivirus, cell-based assays, and NGS—give the site additional agility. By aligning physical infrastructure with anticipated areas of growth, the facility positions itself to remain relevant even as therapeutic pipelines shift.
The role of client collaboration
Designed with modular layouts, advanced digital infrastructure, and dedicated suites, the RTP facility offers the flexibility to adapt quickly as scientific needs and therapeutic pipelines evolve. Image: Courtesy of Solvias
One of the defining features of the RTP expansion was how deeply customer input shaped the final design. Solvias relied on “voice of the customer” surveys and technical visits, treating clients not just as end-users but as strategic partners.
Insights gathered from Phase 1 operations fed directly into Phase 2 planning, allowing the team to refine lab layouts and workflows in response to real-world experience. “[The] clients wanted a partner that could scale with them. This led to the inclusion of modular lab spaces that can be reconfigured as needs evolve”, Hepler says.
This feedback loop not only built trust with customers but also ensured the facility reflected genuine market demand rather than internal assumptions. For lab planners, this is a critical takeaway: involving clients early and often can de-risk design decisions while creating facilities that are more aligned with operational realities.
Lessons from an accelerated timeline
The RTP site went from shell space to an operational, cGMP-compliant laboratory in roughly a year—a timeline that left little room for error. For Solvias, success came down to strong partnerships and disciplined project management.
“The biggest lesson learned is how important the partnership is between the owners, construction, engineering, and design teams,” Hepler says. “This project was completed on time and under budget with less than 0.05 percent in design change orders.”
Clear communication and early alignment across all stakeholders were critical in avoiding costly rework. By keeping change orders to a minimum, the project maintained both schedule and budget discipline—something many fast-tracked lab projects struggle to achieve.
The RTP expansion represents more than additional laboratory space. It is Solvias’ sixth Center of Excellence globally and its second site in North America, solidifying its role as a partner in the US market for complex analytical services. The investment allows Solvias to meet surging demand for specialized biologics testing while providing a platform that can adapt as the science evolves.
By embedding agility into both the design and construction processes, Solvias has positioned itself to respond rapidly to client needs and accelerate the time-to-market for advanced therapies.
Actionable takeaways for lab planners and builders
The RTP case study demonstrates how phased expansion, modular design, early integration of digital infrastructure, and strong partnerships can help architects and project leaders deliver cGMP-ready facilities on time and on budget. Image: Courtesy of Solvias
For architects, lab planners, and project leaders, the RTP case offers several key lessons:
Phased expansion mitigates risk: Starting small and scaling up allows organizations to validate workflows, incorporate feedback, and reduce financial exposure while still building momentum.
Design for modularity and reconfigurability: Flexible lab layouts, dedicated suites, and automation-friendly infrastructure ensure facilities can evolve without major renovations.
Embed digital infrastructure early: Scalable data systems not only streamline regulatory compliance but also prepare facilities for the ever-increasing data demands of modern science.
Engage clients as strategic partners: “Voice of the customer” processes can directly shape design decisions, resulting in facilities that better reflect market needs and enhance client trust.
Strong partnerships drive timely delivery: Achieving cGMP readiness in just over a year required close collaboration between owners, designers, engineers, and construction teams. Minimizing design change orders was essential to staying on schedule and on budget.
Solvias’ RTP Center of Excellence illustrates how thoughtful design and phased construction can deliver both speed and flexibility in the face of a rapidly evolving scientific landscape. By prioritizing modularity, digital infrastructure, and client collaboration, the project created a facility that is not only cGMP-ready today but also prepared for tomorrow’s therapeutic challenges.
The RTP expansion illustrates how laboratories benefit from being planned not only for present needs but also with flexibility to accommodate future demands.
