Rolls-Royce

Banded Stator Facility

Applied recently provided design services for the mechanical infrastructure systems of the new Rolls-Royce manufacturing facility in Indianapolis. The 82,000-square-foot facility is located in an industrial complex near the Indianapolis International Airport and will manufacture Compressor Banded Stators and other components for aircraft engines.

This design-build project converted an existing warehouse space into an advanced manufacturing facility and includes:

  • Four 35,000 cfm air handlers and distribution ductwork in the main manufacturing space
  • Three 900 gpm cooling towers, pumps and distribution piping
  • Three 850 scfm compressors, expansion tanks, dryers, filters and distribution piping
  • A process gas tank farm to supply hydrogen, nitrogen and argon to the facility
  • New city water, sanitary and natural gas services
  • Other mechanical systems including office HVAC, water softeners and instantaneous water heaters
  • A building automation system

The facility employed an innovative process water system that recycles the waste water stream from manufacturing processes rather than discarding it. The waste particles are removed from the system through several filtration stages, and treatment chemicals are added to bring the supply water into tolerances required for the process users. The filtered and treated water is pumped out to the manufacturing floor.

The mechanical infrastructure improvements were part of architectural and electrical improvements completed in December 2012. Process manufacturing equipment will be installed in the next phase. The entire installation is expected to be completed in 2014 at a cost of $42 million. Applied served as a subconsultant to DEEM on this project.