Scaling Up Facilities for Aerospace Manufacturing
High-Temperature Composites Expansion | Cypress, California
DPR expanded an advanced facility for a confidential top-10 aerospace firm, transitioning high-temperature composite (HTC) manufacturing from lab-scale to validation. The project includes mechanical, structural, and electrical upgrades, integrating new equipment and process utilities to validate manufacturability before scaling production.
About the Project
The HTC expansion supports the development of components for next-generation aircraft engines. Transitioning from lab-scale capability to a pre-production validation scale, the project serves as the next step toward a future low-rate initial production (LRIP) facility.
Work took place within an existing 10,000-sq.-ft. unfinished first-floor space, adding a new air handling unit (AHU) and building envelope changes to support both the AHU and a furnace. Other work included interior architectural upgrades, floor plan modifications for new manufacturing equipment, minor site work, fire suppression enhancements, and upgrades to critical utilities and communications infrastructure to prevent potential service disruptions.
Challenges and Solutions
High-Performing Team
As with many other enhancement projects on operating facilities, one of DPR’s first goals was to align with the “Rules of the Road” of the client’s onsite Operations team. This ensured our workforce maintained safety and operations protocols and caused the least disruption possible. Communicating in biweekly meetings on progress and coordinating adjustments with all stakeholders, DPR earned the client’s trust and created a safer and more efficient project.
Early Design Involvement
DPR team members were engaged early in design to purchase long-lead equipment, give constructability input, and help with schedule and budget development. Construction was out in front of the design in several areas. There were three iterations of design development, which required budget and schedule revisions, and resequencing work along with new permitting. These occurred while the base project was moving forward. Through detailed schedule workshops, DPR was able to minimize delays.
Laser Scanning and BIM Modeling
Our VDC team used laser scanning of existing conditions and incorporated the scan into a virtual design model for all trades to draw and plan the installation to avoid conflicts. This included incorporating the model of the furnace into the construction model to lock in all Points of Connection. The model served as a crucial tool to enhance planning, avoid rework, and perform efficient installation of the many systems comprising the key elements of the project.
Challenges and
Solutions
High-Performing Team
As with many other enhancement projects on operating facilities, one of DPR’s first goals was to align with the “Rules of the Road” of the client’s onsite Operations team. This ensured our workforce maintained safety and operations protocols and caused the least disruption possible. Communicating in biweekly meetings on progress and coordinating adjustments with all stakeholders, DPR earned the client’s trust and created a safer and more efficient project.
Early Design Involvement
DPR team members were engaged early in design to purchase long-lead equipment, give constructability input, and help with schedule and budget development. Construction was out in front of the design in several areas. There were three iterations of design development, which required budget and schedule revisions, and resequencing work along with new permitting. These occurred while the base project was moving forward. Through detailed schedule workshops, DPR was able to minimize delays.
Laser Scanning and BIM Modeling
Our VDC team used laser scanning of existing conditions and incorporated the scan into a virtual design model for all trades to draw and plan the installation to avoid conflicts. This included incorporating the model of the furnace into the construction model to lock in all Points of Connection. The model served as a crucial tool to enhance planning, avoid rework, and perform efficient installation of the many systems comprising the key elements of the project.
We think you'll like this, too.
