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

e: manorbierstation@tiscali.co.uk

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