Spirit AeroSystems Center for Composite Excellence

Project Team

Structural Engineer: Haskell Architects and Engineers 
Owner: Spirit AeroSystems
Architect: Haskell Architects and Engineers
General Contractor: Haskell 
Steel Joist Manufacturer: Vulcraft
Steel Detailer: Southeast Steel Detailers 
Steel Fabricator: Haskell 
Steel Erector: Summit Steel Erectors 

Project Type: Industrial

Project Description

The Spirit AeroSystems Center for Composite Excellence, located in Kinston, North Carolina, is the third aero structure manufacturing facility that Spirit AeroSystems has engaged Haskell’s Design-Build expertise on in the last three years. The 585,000 square foot structural steel framed building with insulated metal panel envelope is used to manufacture composite aero structure components for the Airbus A-350. The fully environmentally controlled facility consists of 150,000-square-foot Class 100K-ISO8 Clean Room environments, 170,000-square-foot Fabrication and Assembly rooms, a specialized room for one of the world's largest autoclave units, as well as Tooling Maintenance and Prep areas.

What Makes This Project Interesting

The key design challenge was to address the overall size and scale of the composite sections being produced within this facility. The S-15 Panel and Spar sections being fabricated are in excess of 46 feet long and 18 feet wide. The manufacturing process required large clear spans with ample clearances to maneuver large tools carrying the product without distribution of the process. To create these large, column-free areas, 10 foot-deep joist girders were used to span between 100 feet and 173 feet; supporting joists up to 131 feet, 4 inches long. In addition, the roof structure was required to support multiple 10- and 15-ton bridge cranes, as well as walk-on ceilings, while maintaining the stringent deflection criteria l/600 to satisfy the crane manufacturer requirements (the largest crane zone covered 76,000 square feet without any intermediate columns). The transportation core connects all manufacturing areas and supports all mechanical and electrical equipment on a 580-foot long mezzanine.
 
 

Advantages Of The Chosen Structural System

The joist and joist girder framing was the most economical structural solution to create large, column-free areas. In addition, the joist manufacturer’s engineering staff's expertise allowed the project to stay on schedule during design, fabrication and erection. Panelized construction methods of the roof accelerated the overall steel erection schedule. Overall, 3,500 tons of joists, 600 tons of roof deck and 4,000 tons of structural steel were erected in approximately three months. 
 
 

Project Scope

The scope of the project included foundations, slabs on grade and superstructure for Spirit AeroSystem’s new composite material facility in North Carolina. Besides the main building contract, more than 60 additional contracts were executed, which included the design and construction of office spaces, freezer building and special equipment foundations. All of the 585,000-square-foot roof structure and the 47,000-square-foot mechanical mezzanine were constructed with bar joists, bowstring joists and joist girders. 

Project Details

Project Construction Cost: $116,942,000 
Joist cost, including fabrication and erection: $16,000,000 
Size (square ft.): 585,000
Roof area using joists (square ft.): 585,000
Floor area using joists (square ft.):  47,000
Joist area (square ft.): 632,000
Joist engineering to delivery (# days): 90
Joist erection (# days): 90

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