- Composites Manufacturing & Paint Facility Addition
Our team provided design-build services for a 424,000-square-foot manufacturing facility and paint facility addition. The facility produces composite parts for the client’s commercial aircraft program and is an expansion of an existing tooling center that includes five autoclaves. The existing adjacent facility remained operational during construction.
This project was the 2017 St. Louis Council of Construction Consumers (SLCCC) Construction Industry Best Practices Award Winner.
The design of the main addition was broken into 25 separate construction packages to allow for continuous progression. The packages were developed over a 12-month period involving more than 155 design professionals. Design features included 100-foot-by-100-foot bays, 40-foot building height, auger-cast pile foundation system, custom trusses to support overhead cranes, numerous equipment mezzanines, office and conference room space, a clean room, a network of interconnected catwalks housing HVAC systems, and a new 3,600-ton central utility plant. The facility houses numerous large-scale process equipment such as trim cells, autoclaves, freezers, ovens and automated ultrasonic scanning systems.
The paint facility expansion included a 110-foot free span, high-bay for painting processes, auger-cast pile foundation system, two large equipment mezzanines, office space, locker rooms, overhead utility distribution, paint storage, a blast-rated mix room with deflagration paneling, a custom-designed prep area with “knife edge” down flow stations for large part prep, and an exterior below-grade double containment emergency waste collection system. The facility contains downdraft spray booths, curing ovens, prep areas and a monorail system to move parts swiftly.
- Managing the balance between project budget and process equipment essentials
- Coordinating existing facility to function with new facilities
- Modifying existing structure to withstand additional snow drift
- Maintaining operations of existing clean room during adjacent construction
- Adjusting firewall design due to property line proximity
The combination of design challenges and tight schedule required a creative approach to meet construction milestone dates. We tailored the design methodology and construction packages to match the owner's needs. Additionally, to mitigate possible construction or submittal delays, we used an efficient and effective communication process involving weekly meetings, “over-the-shoulder” in-person design reviews, and topic-focused design sessions. As design progressed, we worked closely with the builder regarding project scope for continuous monitoring of the construction budget. The proven, solid work plan was embraced by all parties.
Our team has worked with this client on more than 125 projects. For this project, we used problem-solving experience from a variety of backgrounds including aerospace facility engineering best practices, 3D integrated modeling, manufacturing process engineering, design-build workflow, construction management, and budget management.
- Construction administration