1The Challenge
An aerospace composite structures manufacturer needed to create a temperature and humidity-controlled lay-up room within their existing production hangar, maintaining 18–22 °C and 45–55% relative humidity for the curing of pre-preg carbon fibre components. The room needed to accommodate a large autoclave and allow movement of large composite panels by overhead crane, requiring a high ceiling clearance and appropriate penetrations for crane rails and services.
2Our Solution
Mercia Industrial worked with the client's mechanical and electrical engineers to design and install a ThermalShield enclosure with 100 mm panels on a purpose-engineered steel frame structure, incorporating crane rail penetrations with purpose-designed sealed collars and a service penetration bulkhead. The access doors were specified as insulated fast-acting roller doors to maintain environmental conditions during panel transfer operations. Full AS9100 compatible documentation was provided for the client's quality management system.
3The Outcome
The lay-up room achieved and has consistently maintained the target temperature and humidity conditions since commissioning. The AS9100 documentation package was accepted without queries by the client's quality team and by their OEM customer on a supplier audit. The facility has successfully cured over 400 composite panel assemblies in the controlled environment since installation.
“Building an enclosure within an aerospace production facility to quality management system requirements is not a task for a general contractor. Mercia's understanding of our documentation requirements and their ability to design around the crane rail constraint made them the right choice.”
— Manufacturing Engineering Manager, Bristol Aerospace Composite Manufacturer
- Client
- Aerospace Manufacturing
- Location
- Bristol, South West England
- Industry
- Aerospace Manufacturing
- Product
- ThermalShield