Morabito Consultants provided structural engineering services for Datwyler Sealing Solutions, a state-of-the-art pharmaceutical manufacturing facility in Middletown, Delaware. The project supports production of critical pharmaceutical components in highly controlled clean room environments, requiring careful coordination between structural systems, process equipment, and stringent anti-contamination standards.
The development includes a large manufacturing facility and multi-story office component designed to support production, administration, laboratory, and visitor functions. The production facility incorporates multi-level mechanical mezzanines and a raised viewing corridor, allowing employees and visitors to observe operations while maintaining separation from clean room environments.
The structural system consists primarily of steel-framed beams and columns supporting bar joists and concrete floor decks, with long-span bar joists and metal deck at the roof. Steel moment frames and braced frames provide lateral resistance, while specialized structural design elements accommodate clean rooms, sterile production areas, blast-resistant spaces, gantry cranes, rooftop ductwork, and process equipment loads.
A key architectural feature of the office building is an open lobby with two-story glass storefronts on multiple elevations, supported by steel tube columns and girts. An exposed second-floor walkway provides unobstructed views into the space, requiring coordinated structural framing to maintain openness, transparency, and visual continuity.
The completed facility reflects a modern, efficient pharmaceutical manufacturing environment that meets advanced clean room production standards while integrating structural systems for production flexibility, specialized equipment, visitor circulation, and architectural intent.