Rolls Royce Advanced Blade Casting Facility

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Case Study Details

January 2014
Bam Construction
Service Type

Client’s Requirements   

Rolls-Royce commissioned the construction of a state of the art advanced blade casting facility in Rotherham. The new facility will manufacture high technology, single crystal turbine blades for large civil aero engines and will create 150 jobs. The new 14,000m2 facility will be one of the most advanced blade casting facilities in the world, featuring 'ground-breaking' manufacturing techniques such as 3D structured light for geometry inspection.

The Advanced Blade Casting Facility (ABCF) also incorporates a large area dedicated to research & development within the factory to allow casting and finishing techniques to be modified including the ‘single crystal’ casting principle.

Silcock Leedham’s Contribution

The ABCF needed a stable and exact internal environment in areas of production, with very different internal criteria for the various process areas.  This required a multi-chamber approach to the design of the Mechanical and Electrical engineering services, so that the required close control requirements could be achieved.

The Wax and Shell areas were particularly onerous in environmental terms, as there was a high level of ceramic drying which resulted in very high evaporation levels and environmental moisture removal.  Silcock Leedham developed an integrated drying facility in the air conditioning system using a combination of desiccant and refrigerated moisture removal techniques.

Added Value / Unique Selling Points

Silcock Leedham acted as Mechanical and Electrical Engineers working with the main contractor BAM Construction on all factory systems, including ventilation, process extract, compressed air, effluent treatment and disposal, chemical delivery, process gas systems, furnace extract systems, HV and LV distribution and the like.

We developed a BIM using REVIT to produce fully coordinated 3D drawings with embedded intelligence incorporating all 3rd Party specialist factory systems such that all ‘handshake’ points between the specialist factory systems and the buildings mechanical and electrical systems could be identified and coordinated with Rolls-Royce suppliers.

The Silcock Leedham BIM and handshake points manual was utilised by all suppliers and specialists as the master coordination and control point and was undated with new information such that at the end of the project the Building Information Model (BIM) could be used for Facilities Management.