Airbus A220 Final Assembly Line (FAL) Expansion

Mobile, Alabama

CLIENT
Airbus Commercial Aircraft

SIZE
269,000-SF

SERVICES
Design Services

As part of a design-build team, BRPH was awarded the design of the new A220 Final Assembly Line (FAL) facility, which produces the Airbus A220 aircraft at Airbus’ Mobile, Alabama manufacturing campus. The FAL encompasses approximately 269,000 SF, comprised of aircraft assembly high bay, a multi-level support annex, administrative support offices, and support space.

The assembly process consists of five stations:

  • Fuselage assembly
  • Wing assembly, wing main gear, engine strut and nose gear
  • Assembly of vertical stabilizer and tail plane
  • Assembly of gear doors, equipment and system tests
  • Installation of interior, engines and APU

A recessed loading dock permits receipt of smaller parts and components via truck. Large aircraft sub-assemblies will enter the high bay through vertical lift doors on the east face, while completed airframes will come out of the building through a large rolling steel hangar door system on the building’s west face. Media channels are provided below the production floor for routing of utility infrastructure supporting the aircraft assembly process. These spaces will be provided with access/egress stairs and lift access to facilitate the placement of large equipment.

The facility superstructure consists of pre-engineered rigid steel frames with standing seam steel roof panels over rigid board insulation on a steel deck supported by steel purlins. The facility exterior walls are  insulated metal panel punctuated with translucent wall panels for daylighting. The facility interior walls, flooring, ceiling, finishes, mechanical and electrical system components match those in the existing A320 FAL hangar and support spaces.

In addition to the new FAL, expansion of the existing Logistics Building was required to support continuing operations and to permit new/existing structures to seamlessly integrate. The pre-engineered superstructure of the building was duplicated westward to extend the existing space and provide dedicated staging in support of the FAL.

The A220 FAL and the Logistics expansion are designed to achieve a USGBC LEED Certified v4 rating.