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Aircraft Storage Facility and Ancillary Operations at Upington Airport in South
Africa The Facilities Requirement
R. Nordberg-2014
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Contents
Foreword
1. Infrastructure Requirement
2. Planning Data
3. Facilities
4. Human Resources
5. Construction Data
6. Baseline Standards
7. AFDA
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Foreword
This document has been compiled for two separate consortia bidding in response to Request for Proposals (RFP’s) by Airports Company of South Africa’ (ACSA)
CORP 245/2014 (Closing date 12th May 2014)
‘Aircraft Storage Facility & Ancillary Operations at Upington Airport, Northern Cape Province of
South Africa’
CORP 415/2014 (Closing date 5th November 2014)
‘Appointment of Consultants for the development of Strategic Business model and Approach for the Establishment of an Aviation Park (MRO, storage Recycling etc.} at Upington Airport, Airports Company of South Africa)’
Historical
Acknowledgement: - Transcription & Précis of Airports Company South Africa (ACSA) report, author unknown.
Upington International Airport is a strategic air transport facility located in the Northern Cape Province of South Africa and one of the 10 airports managed and owned by Airports Company South Africa (ACSA). As it is a known fact that capacity to keep aircraft parked is a worldwide problem and with infrastructure capacity in mind, ACSA decided to invest in researching various strategies in an attempt to utilise the extra capacity that Upington has and to increase the commercial revenue stream of the airport.
The strategy of a parking and storage facility of aircraft was decided and seems to be the most realistic initiative to turn the airport into a profit making airport.It is further believed that this project can contribute to being a catalyst for broader and bigger economic growth in the region as well. One major contributing factor that made this option attractive is that this area, besides having the facilities, enjoys extreme warm dry weather conditions that prevail in Upington and surrounding regions with rainfall and strong winds being very limited.
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There are hundreds of aircraft standing in Europe and America to name just a few countries which take up valuable airport space and are in a deteriorating state due to wet weather conditions. Although these aircraft are not a lost cause in total as these aircraft can be serviced, painted and made operational to fly in other countries where they can be accommodated, like in Africa. The basic requirements for a Parking and storage facility for aircraft are as follows:
The runway infrastructure should be able to accommodate the aircraft, general weather conditions, 24 hour security and adequate fire protection services.
Since Upington Airport operates as a Cat 8/9 AFFR conditions and is acommercially driven airport and with the Boeing 747 as design aircraft,it fully meets all the criteria regarding arriving and departing aircraft of all sizes.
Parking will include the planning and development of a site layout plan to provide for short, medium and long-term parking in such a way that aircraft can be drawn from storage without restriction and problems.
Spacing between aircraft will be sufficient to allow the easy access and manoeuvring of vehicles, aircraft, stairs and fire tenders between aircraft.Pavement for the parking area is not necessary, but it should be firm to prevent any sagging of aircraft and should enable the movement of aircraft at all times.
Although not a requirement, it is recommended to park aircraft with their noses into the prevailing wind at the airport.
With the South African Air Force (SAAF) situated next to the Upington Airport, an agreement was concluded between ACSA/SAAF that will allow the parking of aircraft at the SAAF whilst the airport is busy with a R36mil upgrade project consisting of the rehabilitation of all 3 runways and the refurbishment of 50 hectares of ACSA property that has especially been earmarked for the parking of aircraft.
Advanced services for aircraft storage will include the following:
-Aircraft preparation-Maintenance -Removal and reactivation -Record keeping of all activities prior to, during and after storage.
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Maintenance of Aircraft:
During the trip undertaken by Esmaralda Barnes, Airport Manager Upington, to the U.S., it became clear that maintenance is a crucial aspect of the total concept of aircraft storage; it is regarded as essential for the facility at Upington Airport to accommodate this service.
Aircraft Sales is also an aspect of aircraft storage:
Aircraft manufacturers have made it clear that it is in no aircraft owner’s interest just to have it aircraft sold or put back into service, as soon as possible after initial storage. To facilitate this, accessibility of the storage facility is important. Reservation has been expressed about the distance of South Africa from the main aviation centres of the USA and Europe. However, the African market might be emerging and for this reason Upington can have potential especially for the older type of aircraft. At the storage facility, provision must also be made for office accommodation with good communication links and equipment such as photo copiers, computer links etc. for both the aircraft owner’s sales staff and the buyers that normally operate as a team of at least four people. Storage of aircraft documentation is also an aspect that needs to be considered and provided. This documentation will be stored in the belly of the aircraft. Once an aircraft has been sold, the new owner will usually have it painted in their own colours. Seating will also be re-configured. Although it is not essential to have this at the storage area, it will certainly help to create a one-stop service facility, something that can be provided at Upington as well as job creation.
As a last resort, aircraft are torn down and recycled. Aircraft manufacturers maintain that when an aircraft reaches the stage of teardown, that it is an activity that must take place as quickly as possible, and that the whole aircraft should be recycled. Some manufactures are not in favour of stripping aircraft and keeping used spares on a large inventory as this is in direct competition to their OE components. At both the storage facilities visited in the US, teardown and recycling is being conducted, but the areas are untidy and look like a scrap yard, especially at the facility in Kingman. It is however, a service that must be provided.
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1. Infrastructure Requirement
Analysis of the ACSA report conclude that the project requires an infrastructure containing the following facilities to satisfy the aims & aspirations set out in the report.
Aircraft Parking & Manoeuvering
Parking areas for up to 300 Category C aircraft with access lanes for transit to and from the technical area for maintenance or recycling.
Taxiway to & from main runway
Aircraft Servicing Platform (ASP) & floodlighting
Maintenance & Repair Organisation (MRO)
Maintenance Hangars, workshops, management & amenities
Corrosion Control Surface Finishing & Paint Hangar
Wash Rack
Installed Engine Test Facility (IETF)
Fixed Base Operations (FBO)
FBOs offer aircraft fuel, oil, parking, hangar storage, maintenance, aircraft charter or rental, flight training & ground services.
Space to accommodate FBO services described above are incorporated into the overall plan.
Recycling & Reclamation
Hangars, workshops, management & amenities
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2. Planning Data a) Site Layout Plan
The upper half of areas B & all of area C are designated for parking & storing Category C aircraft. The lower half of area B has been designated as the Technical site with an area of 12 Hectares and perimeter of 1660 meters.
b) Technical Site Plan (Reference dimensions are the hangars at 50m x 50m, ignore 1:25 scale)
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c) Aircraft
Category C aircraft have wing Span of 24m to 36m and an undercarriage track of 6m to 9m.
The Airbus A 320-200 is a typical example of a Cat. C aircraft and is used as a template for facility design purposes.
A320-200 Wingspan 34.1 m
Length37.57m
Height11.76m
Wheel Track7.59m
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d) Aircraft Storage Procedures
Reception
The majority of aircraft arriving at Upington will be flown in by the owner. In some cases aircraft may not capable of flight are delivered by overland transport.
Aircrew are debriefed on arrival and details of in-flight discrepancies recorded, aircraft records are taken into custody. The aircraft is tied down in the receiving area and samples are taken of engine oil, hydraulic fluid and landing gear fluid for analysis by a laboratory. Preparation
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Upington airfield is mostly constructed on sand which can damage aircraft by lodging in crevices causing corrosion to the exterior of the aircraft, ingested into engines causing circumferential cracks in combustion chambers and causing indentations to windscreens and erosion to fiber glass, composite materials and rubber used in radomes, antennae protection panels and de-icing boots, to mitigate the damage the following facilities are required:
Airframe
Installation of protective coverings and closing of all external openings (except drains) Parking/mooring procedures, Installation of safety pins, Washing of aircraft (due to environment, may be repetitive), Landing gear strut servicing, lubricating and protection of the oleo, Tyre inflation and rotation, Fuel system decontamination, Primary and secondary flight control cycling and lubrication, Protection of windows, Inspection of seats and carpet for moisture/mildew if stored in humid environments Preserving lavatories and water systems, and Opening of closets, cabinets, and interior doors to ventilate and prevent mildew.
Engine/Auxiliary Power Unit (APU):
Procedures to operate the engine/APU on an established interval, Complete preservation of the engine/APU Electrical:
Opening/closing of circuit breakers, Battery servicing/disconnection, Removal of batteries from emergency devices such as megaphone, flashlights, power supplies for emergency lights, emergency beacons, etc.
Inventory
During this process a complete inventory of the aircraft is performed to document any missing items. Valuable & Attractive
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items or items subject to deterioration are placed in storage or are disposed of. The aircraft is towed to the designated storage position and secured
Operational Checks:
Procedures to transition the aircraft from preservation to a state acceptable for engine, hydraulic, electrical, fuel and avionics etc.
Recovery
Procedures for Returning to Service
Regardless of what procedures a certificate holder has in its manual on preserving an aircraft in storage, the manual must have procedures on how to return an aircraft to airworthy condition once taken out of storage.
These procedures generally include:
Audit the current status of the aircraft to the maintenance program and comply with required tasks, including Airworthiness Directives, life limited components, certification maintenance requirements, avionics databases, etc.
Conduct other inspections and operational checks, as deemed necessary, based on the amount of time the aircraft was in storage and the environment to which it was exposed.
Conduct any operational check flights or test flights prior to return to service.
Reclamation & Tear down Aircraft is moved to the hangar, all recyclable parts are removed serviced and repaired where necessary and disposed of in accordance with current policy.
The Airframe is then removed to a fenced compound for tear down, all liquids drained off, the reclaimed metal packed into ISO containers for security & shipment. All other material are placed in categorized containers i.e. Plastic/Acrylic, Rubber, Fiber glass etc.
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e) Maintenance & Repair Procedures
MRO Hangar: - Restoration of Storage Procedures & Preservation of Aircraft Systems- Scheduled (Periodic) & non-scheduled maintenance inspections. - Calibration, repair or replacement of damaged or unserviceable components, parts and assemblies - Emergency manufacture of non-available parts. - Incorporation of modifications.
To calculate the spatial requirements of an aircraft MRO hangar an understanding of aircraft maintenance and inspection activities are required. Periodic checks are required after a certain amount of time or usage: -
Checks A & B can be carried out overnight at an airport gate and include:
- Pre and post flight/use checks- Replenishment of fuel, oils & gases- Dispatch and recovery of aircraft- Ground handling & documentation control
Checks C & D are carried out in a Hangar and include:
- Scheduled (Periodic) & non-scheduled maintenance inspections. - Calibration, repair or replacement of damaged or unserviceable components, parts and assemblies - Emergency manufacture of non-available parts. - Incorporation of modifications.
f) Components & Equipment
Aircraft Components requiring Maintenance, Repair & Testing
Hydraulic AccumulatorActuatorHydraulic Generator
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Metering ValvePower Control Unit Yaw DamperPower Transfer UnitHorizontal Trim Stabiliser Hydraulic MotorElectric Motor PumpPump
Pneumatic
Air Cycle Machine Air StarterWater SeparatorFlow & HP control valveSafety valve
Flight Control Surface
AileronsDorsal Fin AssemblyElevatorsFlapsHorizontal StabiliserRudderRudder TabSlatSpoilerVertical StabiliserEngine Driven Pump
Aircraft Door & Access Panels
Cockpit DoorMain Landing Gear DoorNose Landing Gear DoorOther Doors & Panels
Interior
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Floor panelGalleyLavatoryOverhead binSidewall Panel
Aircraft Structure
Exhaust ConesExhaust NozzlesFan CowlsInlet CowlNacellePressure DoorPylonStrutRadomeTailconeThrust ReverserWing tipWing to body fairing
Transmission
Flap transmission, Ball screw, Snubber & Gearbox
Electrical, Instrument & Avionics
Electrical & Instrument Equipment Radar/Communications/Navigation Aids Batteries Generators/Actuators/Inverte
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g) AIRCRAFT MAINTENANCE EQUIPMENT
Chocks, Covers, Blanks
Earthing leads
Undercarriage & Flying control surfaces Safety Struts
Cockpit access Ladders
Staging
Main & Nose-wheel Jacks, Pads & Airframe Lift Eye Bolts
Wing/Tailplane Trestles & Stands
Mobile Steps & Access Platforms
Hydraulic & Engine Oil Replenishment Equipment
Liquid & Gaseous Oxygen Replenishment Equipment
Air & Nitrogen Replenishment Equipment
Diesel/ Electric & Electric/Electric generation sets
Aviation refuel/defuel Equipment
Aircraft Washing Trolley
Aircraft Specialist Tools & Control Surface measurement
Mobile crane & Fork lifts
Tractors/Tugs & Trailers
Low Loaders
Cutting Equipment
First Aid Fire Fighting Vehicle
Crash Kit
Various Salvage Trolleys (Tracjacs)
Airbags15
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h) COMPONENT MAINTENANCE & TEST EQUIPMENT
AIRFRAME, STRUCTURAL & NDI (Does not include specialist test equipment)
WHEEL TYRE & BRAKES
Nitrogen Replenishment Trolley Rotojet Washing Machine - 415V Wheel Servicing Stand
Nose wheel Servicing Adapter plate
Main wheel Servicing Adapter plate Hydraulic Press Tyre Inflation Cage Wheel Storage Stand
Tyre Removal Rig
Oven 0-300deg C
HYDRAULICS
Hydraulic Test Bench - 415VOil Sampling KitHydraulic Rig Aircraft – 415VCabin Pressure Test Rig - 415V
PNEUMATICS
Pneumatic Component Test Bench
STRUCTURES
Pillar DrillGuillotine
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Bending MachineSheet Metal Rack
NDI
Radiographic, Ultraviolet, Eddy Current, Ultrasonic, Optic, Penetrant, Magnetic, Infrared
PROPULSION (Does not include specialist test equipment)
Engine Change Kit, Cradles & Trolleys
GENERAL ENGINEERING (Does not include specialist test equipment)
Pillar DrillWelding EquipmentPaint Spraying Equipment
AVIONICS, ELECTRICAL & INSTRUMENT (Does not include specialist test equipment)
Battery Charger analysersGenerator Test RigRotary Actuator Test RigLinear Actuator Test RigInverter Test RigAC/DC CalibratorsMultimeters OscilloscopesOhmmetersFrequency metersInsulation testers
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3. Facilities
MRO & Recycling
A 4 - Bay Hangar with sufficient floor space to carry out maintenance, repair & storage on Category C aircraft.
Administration, Management & Amenities Offices for Reception, Business & Administration Conference & Hospitality Room Male Amenities Female Amenities First Aid Crew room & Kitchen Executive Suite & Aircraft Representatives
Maintenance Management
Aircrew Operations & Planning RoomEngineering Managers’ OfficeChief Engineers’ OfficeHangar Tool StoreLibrary & Technical DocumentsDrawing & Design, Reprographics, Archives & IT server
Airframe Shop
StructuresWheels, Tyres, Brakes & CleaningCanopy, Transparencies & Composites Non- Destructive Inspection (NDI) Hydraulic & Pneumatics
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Propulsion Shop
Engine Auxiliary Power Unit Cleaning Early Failure Detection Cell (EFDC)
Electrical, Instrument & Avionics Shop
Electrical & Instrument Radar/Communications/Navigation Aids Battery/Generators/Actuators/Inverters
Safety & Survival Shop
GalleyPassenger Service Unit Passenger Seat/Crew Seat Life Raft & Emergency Evacuation Slides
Life preserver Oxygen masks & cylinders Cargo nets & straps
Ground Support Engineering Shop
Lifting Tackle, Winches, Slings, Strops & Cables Workshop & Inspection Pits Welding, Painting & Carpentry shops Tool Store
Logistics Organisation
Logistics Manager- Office Receipt & Dispatch, V&A, Adhesives Store Hazardous materials (HAZMAT) Store Gas Cylinder compound Industrial & Domestic Waste compound
Recycling A 2-bay hangar for tear down and recycling operations with Workshops, administration, control & amenities.
Secure compounds for the storage of specialist GSE & storage 19
of valuable recycled material
Support
First Aid Fire Fighting Apparatus (FAFA) station Crash Recovery equipment compound Vehicle re-fuelling station Heavy goods Vehicle, ISO container & car parking
Surface Finishing & Paint Facility
A single bay hangar with an air conditioning system designed to maintain the temperature & humidity of the air at predetermined levels, the air also requires to be scrubbed & cleaned to remove any solvents.
The hangar volume therefore should be reduced to the minimum needed for the biggest type of aircraft.
To minimise the volume of the air to be controlled, cleaned & scrubbed the following features are required:
- An insulated ceiling over the entire area, at as low a height as practicable approximately 2m(6ft) all round & 1m(3ft) above
- Partitioning off the triangles in front of the wings
- A small nose hangar
- An insulated tail box near the front door for the aircraft rudder.20
Ground Support Equipment and Motor Vehicles
A permanent building will be required to manage, control and maintain: Ground Support Equipment for:
- Aircraft Ground Power - Hydraulic Servicing - Air starting - Cabin pressure test - Aircraft Washing
- Air conditioning - Jacks
Motor Vehicles:
- Fire - Refueling- Tugs, Tractors & Push backs
Ramp Support Equipment:
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- Potable Water Trucks- Lavatory Servicing Vehicles
- Boarding Stairs
The facility consists of workshops & offices, vehicle park & shelters.
Aviation Training School
To provide students the specialist training & basic skills required for Licenced Aircraft Engineers, through direct entry or an aircraft apprenticeship.
The school facilities can be adapted for basic flight training.
a) Option 1As part of the MRO hangar complex with classrooms for Computer Based Training, Computer Aided Instruction and Demonstration Rigs for theoretical instruction, aircraft on the MRO hangar floor and workshops for practical instruction.
b) Option 2As a separate new build with classrooms for Computer Based Training, Computer Aided Instruction, and Demonstration Rigs for theoretical instruction, provision made to construct a small hangar attached to the school housing a small aircraft & helicopters for practical instruction.
Both options comprising of:
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- Reception, Offices, Toilets & Locker Room - Common room, Library/Self Study Room - Classrooms - Instructors & Authoring Office
- Aircraft Systems Demonstration Rigs - Hangar (option 2 only)
4. Human Resources
The manpower & job descriptions listed below serve to illustrate the human resources required to operate the MRO & Recycling Facility:-
Permanent Staff:
General Manager
Engineering Manager
Chief Engineer – Mechanical (Airframe& Propulsion)
Deputy Chief Engineer – Airframe Specialist Engineers – Airframe
Deputy Chief Engineer – Propulsion Specialist Engineers – Propulsion
Chief Engineer – Non Destructive Testing
Deputy Chief Engineer - Non Destructive Testing Specialist Engineers - Non Destructive Testing
Chief Engineer – Electrical, Instruments & Avionics
Deputy Chief Engineer – Electrical & Instruments Specialist Engineers – Electrical & Instruments
Deputy Chief Engineer – Avionics Specialist Engineers – Avionics
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Chief Engineer - Safety & Survival
Deputy Chief Engineer - Safety & Survival Specialist Engineers - Safety & Survival
Chief Engineer- Ground Support Equipment
Deputy Chief Engineer – GSE &Vehicles Specialist Engineers - Ground Support Equipment Specialist Engineers - Vehicles
Chief Engineer- Corrosion control & surface finisher
Deputy Chief - Corrosion control & surface finisher Specialist Corrosion control & surface finishers
Deputy Manager -Technical Documentation
Supervisor -Technical Documentation
Specialists -Technical Documentation
Deputy Manager - Finance & Administration
Supervisor - Finance & Administration Administrators- Finance & Administration
Deputy Manager- Recycling Operations Specialist Engineers – Recycling & Tear down
Principal – Aviation Training School
Chief Instructor Specialist Instructors
Temporary Staff & Contracted Services:
Security Refueling/defuel I.T., office and communications Painting & Finishing
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Janitorial, Facility repair & maintenanceTest Pilots & Aircraft Owners RepresentativesClerical & Receptionist Students & Apprentices Transport Waste Disposal
5. Construction Data
Exterior General Arrangement
SitingDimensionsMaterial Specifications- Walls & RoofAccess - Ramped, Stepped, KerbedType of Surface/Load Carrying CapacityClearances & ObstructionsCar Parking
Interior General Arrangement
Room usage, floor plan with identification and occupancy Floor levels – raised, cavity space for cable runs Floor Loadings, surface covering, trench layout & dimensions Material specification of walls floor & ceiling Doors, Windows, Openings & Apertures
. Environmental Requirements
Air- conditioningTemperature/humidityCleanliness standardVentilation & fume extractionLocation & type of drains (e.g. containment or separation)NoiseEquipment cooling
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Mechanical Requirements
Gas/Fluid Outlets
Type of gas or fluidPressuresFlow RateType of Connector
Lighting
EmergencyExplosion proofAnti – glareNon – stroboscopic
Furniture, Fixtures, and Equipment
Dimensions Location & orientation Accessibility Safety requirements Service plinths/ISO pits
Lifting
Gantry hoists Safe working load (SWL)
Traversing axes
Hook height Electrical or manual
Emergency/Security/Communications/Safety
Fire detection & suppressionSecurity systems (e.g. access control, alarms, and warning lights)
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Communication systems (e.g. Telephones, Intercom, tannoy, IT systems)Lightning protection & Earth (Grounding)
R 6. Baseline Standards
BUILDING
Ceiling Heights
Offices: - 2400 mm
Workshops:
Structures & Propulsion - 6000 mm
The remainder - 3000 mm
Corridors: - 1500 mm & 2000m
Doors:
Single - 900 x 2300 mm
Double -1800 x 2300 mm
Furniture
Workbenches:
Mechanical - 1500 x 915 x 915 mm
Avionic - 1830 x 915 x 915 mm
Workshop stool & chair: Industry standard
Office desk and chair: ‘L’ shaped computer office standard
Cabinet/Cupboard: - 1000 x 1500 x 180 mm
Racking: Heavy - 2000 x 750 x 2000 mm Light - 1000 x 400 x 1800 mm
Filing Cabinet: - 470 x 620 x 1500 mm
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Notice Board: - 2000 x 25 x 1500 mm
Tool board: - 1000 x 25 x 1000 mm
ENVIRONMENT
BS 5295 - Class L for Avionics & Hydraulic reassembly
- Class M for all other areas
ELECTRICAL
Domestic: National Standard
Aircraft: ISO1540- 115/200Volts 3- Phase 400 Hertz 28 Volt d.c. Workshop ISO 6858-115/200Volts 3- Phase 400 Hertz 28 Volt d.c.
WORKSHOP AIR 7litres/sec @ 7 bar
CAR PARKING
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7. Aerospace Facilities Definition Agency
AFDA AEROSPACE FACILITIES DEFINITION AGENCY
About AFDA
AFDA was established to provide expert planning & construction advice for MRO hangars & workshops, Air & Ground crew training schools, Logistics & Ground Support Equipment facilities.
AFDA’s process provides an overview of facilities for the Project Master Plan and detailed data for facility design & construction.
Process
Pre-Survey
After preliminary discussions, AFDA will compile sketch plans showing existing & proposed facilities their dimensions & interrelationships for inclusion into the project Master Plan covering:
Air & ground operational and management facilities Maintenance hangars & ground support equipment Maintenance workshops & equipment Flight simulators & training facilities Logistics & Storage
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Survey
A detailed survey will then be undertaken using guidelines based on:
Operational policy
Maintenance philosophy Planning assumptions & constraints Existing facilities & equipment Aircraft delivery and operational dates
Post Survey
On completion of the survey AFDA will compile Individual Facilities Data Packages (FDP’s) for Architects & Civil Engineers to design, construct, install & commission facilities through face – to - face meetings.
Construction
During the Construction phase AFDA will be available to carry out checks at the mid- point of the construction programmeand at the Installation & Commissioning of the facilities.
Specialist ProfileRichard Nordberg
Royal Air Force: - Aircraft Apprentice- Aircraft Electronic Systems Technician
Airwork Ltd: - Deputy Chief Systems Engineer
BAE Systems: - Logistics, Facilities & Ground Support Equipment Specialist
Contact: Station House, Manorbier, Pembrokeshire, SA70 7SN
t: + 44(0)1834 871973
m: + 44(0) 7811612579
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