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Boeing 777X Composite Wing Center (Building 40-58) hero image

Setting New Performance and Safety Standards for Large Industrial Projects

Boeing 777X Composite Wing Center (Building 40‑58)

Hoffman’s innovations meet an aggressive schedule and save over $4M in costs as the team works five million hours without a Lost Time Accident.

Hoffman broke ground on this massive 1.6 million-square-foot facility in October 2014 and finished the project just 18 months later. The building encompasses 200,000 SF of high bay manufacturing space utilizing a 350’ clear span structure and 150,000 SF of flanking support and office spaces. The plant houses sophisticated robotics tools, complex mechanical and specialty piping systems, and three 120-foot long autoclaves, the pressure vessels used to cure the carbon composite wings of the 777X aircraft. Hoffman self-performed all concrete work and much of the mechanical scope. We developed several cost saving innovations on the project, including a “Traversing Scaffold System” which allowed the high bay work to be performed concurrently with work on the factory floor, saving over $4M in installation costs savings and improving safety. We also created an innovative seam connection for the ultra-flat factory floor which improves long-term durability and performance and saves significant maintenance costs. Hoffman worked five million hours without a Lost Time Accident and received Boeing’s Gold Star supplier excellence award for six consecutive quarters.
Eight chillers and six cooling towers provide 12,000 tons of cooling capacity for the 777X Composite Wing Center and the entire Boeing campus. Five 5,000 GPM chilled water pumps are driven by 350 electric motors inside the 25,682 SF facility. Hoffman met an aggressive schedule so the old chiller building could be demolished, using an elevated work platform to work above and below the chillers simultaneously.

Challenge

Meet an aggressive schedule to bring a major manufacturing facility on line.

Solution

Hoffman self-performed all concrete work and much of the mechanical scope. We also developed several innovations on the project, including a “Traversing Scaffold System” which allowed the high bay work to be performed concurrently with work on the factory floor.

Contract Type

CM-at-Risk

Client

Boeing

Architect

BRPH

Location

Everett, WA

Year

2019

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