Opportunity
In 2012, after considering 70 sites in 32 states, Airbus chose the Brookley Aeroplex in Mobile, Alabama, to assemble its A320 airliners. The decision would make Airbus the first new manufacturer of large commercial aircraft in the US in more than 40 years.
In an article for CNBC, Airbus Americas chairman Allan McArtor wrote, “The decision to construct a plant in this country represents the most significant, game-changing event in US aerospace in decades and is a positive step-change in the longstanding relationship between Airbus and US industry.”
Solution
Mott MacDonald was selected to provide program management services for the design and construction of the Airbus Final Assembly Line, in association with Hoar Program Management. The construction site has a net effective area of about 232 acres (94 hectares), with about 74 acres (30 hectares) occupied by the Final Assembly Line.
As the lead Design Manager, we oversaw all design aspects of the project, including procurement of design consultants, peer reviews of design submittals, and permitting assistance and oversight. We were also responsible for the Enabling Works design, a fast-track approach to preparing the site for construction.
A Project Manager was assigned to each of the following elements of the project, and was responsible for consultant selection, procurement, design management, and incremental construction oversight.
- Final Assembly Line, Service Building, Logistics Center
- Final Phase/Flightline Hangar, Gauging Hangar, Delivery Center
- Transshipment Hangar, Main Gate
- Site Surfaces, Utilities and Infrastructure
We were also responsible for the certified topographic survey, design of a permanent stormwater conveyance system, and a variety of permits.
Outcome
Breaking ground at the construction site in April 2013, Airbus CEO Fabrice Brégier said, “Building an A320 family assembly line in Mobile is truly groundbreaking for Airbus. Our customers need more aircraft that cut fuel burn, emissions and operating costs. With this assembly line we will be able to meet our customers’ needs at their doorstep, in addition to the worldwide demand for these efficient aircraft. When the line opens, we will be the only maker to assemble aircraft in Asia, Americas and Europe.”
In May 2020, a new 270,000 square-foot hangar opened for business after 18 months of construction.
In April 2023, Spirit Airlines welcomes its 200th aircraft from Airbus. In May 2023, Airbus celebrated the production of its 100th US-made Airbus A320A for Delta Air Lines.
As of 2023 the Final Assembly Line employed more than 1,600 people and produced both A320 and A220 Family aircraft.
Watch an interview with Airbus CEO Fabrice Brégier, highlights from the project’s announcement event, and the erection of the final truss of the Final Assembly Line building.