Case Study

Airbus Structural Design Projects

Project Overview
Client Airbus in the UK Location Bristol Project Value 15m combined Services Provided Structural engineering consultancy Added Value By working closely with Airbus to understand their requirements, Hydrock Structures1 has ensured best value solutions are provided through integral design, whilst meeting ambitious programme times.

Large-scale industrial projects provide unique challenges, but by fully understanding the requirements and working collaboratively, we deliver exactly what the client needs. Mark Seberry, Associate Overview Hydrock Structures1 has been involved in a series of significant projects on the Airbus site in Filton, Bristol over recent years. The key element of these projects has been the way in which Hydrock Structures1 has worked closely and collaboratively with Airbus to understand their processes and requirements. This enabled the structural solutions to achieve their requirements, whilst avoiding over-specification such that the cost is prohibitive. Landing Gear Test Facility Airbus required a unique facility in which to test the landing gear system for the new A350 aircraft. This included not only the space for the rig itself but the associated workshops and offices. The design was also to allow for the installation of a possible future rig, with an as yet undefined footprint. In collaboration with architect Stride Treglown, Hydrock Structures1 was responsible for the outline design and specification of the superstructure, the substructure and storm and foul water drainage. As part of the design process, detailed assessments of several potential locations were undertaken, including the development of initial foundation schemes from each, so that robust comparisons could be made in order to achieve a best value solution. The build programme was absolutely critical, as the installation of the complex rig structure had been prearranged to allow for the testing schedule. A steel frame was designed specifically around the tight programme, allowing contractor ISG Pearce to complete on time. Fuel Systems Test Facility A covered area was required to house the full-scale testing facility, to be used for

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modelling of the fuel systems within a variety of airplane wings. In addition, the project included the 4-storey office building and workshops that support the testing process. As part of a team with architects DKA , Hydrock Structures1 was responsible for the initial design and specification, including supervision on site. Considerations of the nature of the site (previous uses included munitions testing), along with the cut fill balance and ground conditions, drove the layout and finished floor levels. To meet the key client requirement of a column free space with a roof capable of supporting the overhead crane, an innovative solution combining the stiffness of trussed columns and a trussed roof allowed the free spanning of the 50m width with the use of minimal steelwork. The type and specification of materials required careful consideration rather than the application of standard solutions. A relatively unusual feature of this project was the requirement to control the obvious fire and contamination risks associated with the large volume of airline fuel used on the site. This in part drove the decision to specify an open-sided structure. To reduce the risk of fire spread, a bespoke sprinkler system was included, and a reinforced concrete bunding system with powered shutters allowed for potential fuel spills to be contained within the buildings perimeter. Despite the industrial nature of the project, Hydrock Structures1 has added architectural quality to the buildings whilst fulfilling a complex set of functional requirements.
Head Office Bristol Birmingham Camborne Manchester Plymouth Taunton T 01454 619533 T 0121 5069040 T 01209 719037 T 0161 9242378 T 01752 347515 T 01823 282981 E bristol@hydrock.com E birmingham@hydrock.com E camborne@hydrockbh.com E manchester@hydrock.com E plymouth@hydrock.com E taunton@hydrockbh.com Bristol Central Gloucester Northampton Stoke-on-Trent Woking

Photographs 1. Fuel Systems Test Facility under construction 2. Office buildings and workshops from the Fuel Systems Test Facility under construction 3. Fuel Systems Test Facility during final stages 4. Entrance of the Landing Gear Test Facility under construction

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