787 Dreamliner Final Assembly and Delivery Facility
The Boeing Company
Charleston, SC

Wood Harbinger met a very aggressive schedule to achieve Boeing’s occupancy and production requirements.

The new facility was built to meet the growing demand for the 787 Dreamliner aircraft.

The Boeing Company, the world’s pre-eminent aircraft manufacturer, embarked on an effort to build a new 787 Dreamliner manufacturing facility in Charleston, South Carolina. This new facility is the second manufacturing line for the aircraft due to the increasing number of orders received for Boeing’s coveted Dreamliner. Assembled portions of the airplane will be flown to Charleston where Boeing will assemble the aircraft. Wood Harbinger’s contribution to this new facility was to provide a facility infrastructure and tool utility design.

Many challenges were presented and overcome during the design and construction on this project. The design team met an aggressive schedule where the scope and design requirements were often developed concurrently with detailed design and construction. Maintaining the schedule was a critical requirement in order to meet the occupancy date.

Innovations of this project included designing the point-of-connection for all the utilities inside tunnels under the airplane assembly areas including 6,000 psi hydraulics, compressed air, potable water, aqueous wash water (filtered and heated), aqueous wash drains (including trench drain system), confined space ventilation, and pumped industrial waste. The accessible connections were precisely positioned for the appropriate tools in use at each production position. Other designed support systems in the tunnels and support shops included tunnel ventilation, pumped waste systems, vacuum systems for three and five axis mill machines, vacuum systems for grinders and sanders, exhaust systems for wet dust collectors, shop compressed air outlets, coolant mixing stations, sinks for hazardous material, exhaust ventilation for alodine/passivation tables, and fire protection routing.

The Wood Harbinger team quickly developed practical design solutions, managed the concurrent development and implementation of plans, and participated directly in Boeing’s 787 design/build processes.