Following initial workshops in the region, the team worked remotely and used time zone differences to quickly advance the design.
This confidential project included the design and construction of a purpose-built facility to manufacture unidirectional tape—a toughened epoxy pre-impregnated carbon fiber resin system (prepreg) that satisfies the requirements of a 20-year contract with a world-leading aircraft manufacturer. Stantec was retained as the prime consultant for this design-build project, and our team included a combination of locally-experienced designers and engineers as well as globally-experienced experts in industrial facility planning.
As the product is sensitive to foreign object debris (FOD), the facility needed to be designed to minimize contamination in the manufacturing spaces. Several important measures included separating FOD-sensitive equipment from high traffic areas by barriers, including FOD-free environments, and configuring air handling equipment and air intake systems to provide advanced filtration of incoming and recirculated air. The facility was also designed and constructed to address local climatic conditions (including relatively extreme heat, low humidity, and significant fine airborne sand/dust) and prevent adverse effects to the product or manufacturing equipment and support systems.
Lastly, the design team worked closely with all project shareholders to ensure that the facility meets the requirements of a 2 Pearl Facility under Abu Dhabi’s sustainability initiative, Estidama.
When completed and fully commissioned, the project will be capable of producing nearly 1 million pounds (454,000 kilograms) of prepreg product (in a variety sizes) each year that meets the end users’ stringent requirements.
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