BAE Systems Campus Expansion

To expand the testing and manufacturing capacity at one of BAE Systems Space and Mission Systems (BAE)’s (formerly Ball Aerospace) Colorado campuses, this facility underwent multiple expansion phases that allowed for growth, without impacting existing operations and productivity.  Our meticulous planning prioritized ongoing program needs while maintaining the client’s desired schedule.

The addition connected two existing areas of the complex, including shipping and receiving, multiple 30-ton overhead cranes, aerospace ISO 7 and ISO 8 cleanrooms, a shaker table, open assembly space, pull testing facilities and a thermal vacuum test chamber. The facility has six separate cleanrooms/control rooms and associated office space. Each clean/control room has a dedicated air handler in the mechanical penthouse. Our team was tasked with not only designing the mechanical systems and the routing for built areas but also planning for the future build-out of three additional cleanrooms.

To support the expansion projects, a new central plant facility was designed and brought online before the demolition of the old central plant. This phase also incorporated the relocation of the existing mylar lab and hazardous material storage space.

The most recent phase of the project included the design of a secure cleanroom to allow for a thermal vacuum chamber. This chamber, large enough to hold two railroad cars, will expand BAE’s testing capabilities.

Each expansion within the facility provided a layer of complexity to the multi-phase design, that inspired and challenged our team to find the optimized solutions. The result is an R&D and integration facility that enables BAE Systems to lead, innovate, and advance the aerospace industry.