Basis of Design

Manufacturing Plants for Composite
Aeronautical Components
Riyadh, Kingdom of Saudi Arabia
Detailed Design. Basis of Design. Large Plant
Table of contents
1. INTRODUCTION. PROJECT BACKGROUND AND SCOPE .................................... 4
1.1. Background ................................................................................................. 4
1.1.1. WP1. Proposal for the Aeronautical Components Manufacturing Process .......... 4
1.1.2. WP2. Implementation of the Layout for the Large Plant ................................. 4
1.1.3. WP3. Sizing of the Plant, Offices and other Services ..................................... 4
1.2. Scope of the Concept Design (WP4) ............................................................ 6
2. OCCUPANCY ESTIMATION ............................................................................... 6
3. LAYOUT CONSIDERATIONS ............................................................................. 8
3.1. Plant Layout ................................................................................................ 8
3.2. Office Layout ............................................................................................... 8
4. URBANIZATION .............................................................................................. 9
4.1. Access and Traffic Roads ............................................................................. 9
4.2. Parking Lanes .............................................................................................. 9
4.3. Sidewalk Areas ............................................................................................ 9
4.4. External Lighting ....................................................................................... 10
4.5. Green Areas ............................................................................................... 10
5. FOUNDATIONS .............................................................................................. 10
5.1. Foundations. Office Building. ..................................................................... 11
5.2. Foundations. Plant Area............................................................................. 12
5.3. Special Foundations ................................................................................... 13
5.3.1. Plates Inserted and Levelled over Slab .......................................................15
6. STRUCTURES ................................................................................................ 16
6.1. Office Building ........................................................................................... 16
6.2. Plant Area .................................................................................................. 17
7. ARCHITECTURE ............................................................................................. 20
7.1. Roofs and Water-proofing.......................................................................... 20
7.2. Enclosure, Partitions and Linings ............................................................... 22
7.2.1. Partitions and Linings ...............................................................................22
7.2.2. Clean Areas Walls and Partitions ...............................................................23
7.3. Pavement and False Ceiling ....................................................................... 24
7.3.1. Pavement ...............................................................................................24
7.3.2. False Ceiling ...........................................................................................24

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7.4. Carpentry, Glasswork and Metal Works ..................................................... 24

7.4.1. External Doors ........................................................................................24
7.4.2. Emergency Doors ....................................................................................25
7.4.3. Clean Area..............................................................................................25
7.4.4. Windows ................................................................................................26
7.5. Stairs ......................................................................................................... 27
8. UTILITIES 27
8.1. General Requirements ............................................................................... 27
8.2. Plumbing ................................................................................................... 27
8.3. Hydrology and Storm Drainage System ..................................................... 29
8.4. Irrigation System ...................................................................................... 30
8.5. Sanitary Drainage and Waste Water System .............................................. 30
8.6. Compressed Air System ............................................................................. 30
8.7. Vacuum System ......................................................................................... 31
8.8. HVAC ......................................................................................................... 31
8.8.1. Design Criteria ........................................................................................32
8.8.2. Solution .................................................................................................35
8.9. Fire protection ........................................................................................... 39
8.9.1. Fire Protection Systems ............................................................................40
8.10. Electrical Installations ............................................................................. 41
8.10.1. Applicable Standards ..............................................................................41
8.10.2. Design Criteria ......................................................................................41
8.10.3. Foreseeable Power .................................................................................41
8.10.4. Description of the Low Voltage Electrical Installation ..................................44
8.11. Interior Lighting ...................................................................................... 46
8.11.1. Applicable Standards ..............................................................................46
8.11.2. Design Criteria ......................................................................................46
8.11.3. Description of the installation ..................................................................47
8.12. Ground Connection and Lightning Rod Network ...................................... 48
8.13. Communications Systems ........................................................................ 49
8.14. CCTV and Access Control System ............................................................. 59
8.15. Control System ........................................................................................ 63
8.16. Public Address System (PAS) .................................................................. 64
ANNEXES:
ANNEX 1. GEOTECHNICAL REPORT.

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ANNEX 2. TOPOGRAPHICAL SURVEY.
ANNEX 3. FOUNDATIONS AND STRUCTURES.
ANNEX 4. PLUBING MATH.
ANNEX 5. HYDROLOGY AND STORM DRAINAGE MATH.
ANNEX 6. IRRIGATION MATH.
ANNEX 7. SEWAGE MATH.
ANNEX 8. COMPRESSED AIR MATH.
ANNEX 9. VACUUM MATH.
ANNEX 10. HVAC MATH.
ANNEX 11. ELECTRICAL MATH.
ANNEX 12. FIRE PROTECTION.
ANNEX 13. TELECOMMUNICATIONS SYSTEMS.

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1. INTRODUCTION. PROJECT BACKGROUND AND SCOPE

The purpose of this document is to describe the design elements used in the project for
the design of a composite aeronautic component manufacturing plant located in Riyadh,
Kingdom of Saudi Arabia.
1.1. Background
1.1.1. WP1. Proposal for the Aeronautical Components Manufacturing

Process
The first stage of the project was based on the proposal for the manufacturing process of
several "standard" components, such as lining, fuselage panels, lengthwise and
transverse stabilisers, as well as other components manufactured in composite material
and intended to be integrated in an aeronautical structure.
These components will be manufactured in a production plant, according to their sizes:
• Large Plant: dedicated to the manufacture of components up to 35x7 m.
The work included:
• A report that includes the study, definition and proposal of alternatives to the
manufacturing process for the various small components in question.
• A report that includes the study, definition and proposal of alternatives to the
manufacturing process for the various large components in question.
1.1.2. WP2. Implementation of the Layout for the Large Plant

The production flows defined in the previous section were used to define the necessary
means of production, their location in the plant, their size, the necessary clearance and
transport systems between the various stations. The necessary logistics, maintenance
and inspection areas were also defined. The delivery of these packages corresponded to:
• Layout of the area dedicated to the production of small components.
• Layout of the area dedicated to the production of large components.
1.1.3. WP3. Sizing of the Plant, Offices and other Services

The following items are defined in this document, among others:
• Operation and production requirements:
o Estimate of the number of workers who will work in the plant.
o Number of workers needed to perform tests.
o Number of investigators.

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o Number of design engineers.
o Number of process engineers.
o Other necessary workers (quality, logistics, etc.)
• Architecture/Structure requirements:
o Dimensions for the number of parking spaces.
o Dimensions for offices.
o Dimensions for quality department offices and laboratory.
o Design of meeting romos.
o Design of rest areas, common areas, etc.
o Design of changing rooms and rest rooms.
o Dimensions for ancillary services (transformation centre, compressed air,

other.)
o Definition of working conditions (T and H) in each area defined in the layout.
o Specific air treatment needs, such as filtering, considering the conditions of

the surroundings.
o Design of the areas with loads exceeding 20 kN/m2.
o Identification of sources of vibration, restrictions and insulation requirements.
o Layout design with overall dimensions and necessary clearance.
o Transport. The need for aerial transport, bridge cranes and specific handling
and transport systems.
o Openings for sunlight.
• Requirements for installations:
o Lighting requirements.
o General electrical supply requirements. Power installed.
o Air conditioning project: work conditions in the clean area will require
22ºC+/- 2ºC; to be decided for outside the clean area (using the following as
a reference: 24ºC +/-4ºC).
o Electrical power study for the factories.
o Water supply.
o Wastewater removal network.
o Specific power supplies.
o Definition of the production process waste materials.
o Layout of accesses and evacuation routes.

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o Access control.
This work listed above results in:
• A complete layout of the large plant, including the area dedicated to production
and the rest of the services and offices.
• This report that contains, at least, the solutions to each of the requirements listed
for the large plant.
1.2. Scope of the Concept Design (WP4)

This document establishes the general project criteria and the basis of design for the
development of the foundation, structures, architecture and utilities of the plant and the
offices building.
It must be studied and read together with the specifications and drawings.
2. OCCUPANCY ESTIMATION
Dimensioning of offices and other areas for personnel shall be based on the personnel
requirements shown in the following list:
PERSONNEL NEEDS.
OFFICE PERSONNEL
DIRECTOR 1
HHRR 3
FINANCE 2
SALES 2
PURCHASE 2
IT SUPPORT 2
HEALTH AND SAFETY 1 (*)
PLANT MANAGER 1
SECRETARY 1
MANUFACTURING ENG. 4
TOOLING ENG. 1

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CNC ENG. 2
PROCESS ENG. 2
LOGISTICS ENG. 1
QUALITY ENG. (PROCESS) 2
MAINTENANCE STAFF 2 (*)
CLEANING STAFF (*)
(*) Could be outsourced
PLANT PERSONNEL
WORKERS per SHIFT
RESPONSIBLES OF AREA 2
TEST ENG. (LAB) 1
MOLD PREPARATION 4
LAY UP AFP LARGE 2
LAY UP ATL LARGE 1
US TRIMMING 1
HOT FORMING 2
ASSEMBLY T
2
STRINGERS' INTEGRATION
VACUUM BAGGING 4
CURING 1
DEMOLDING 2
MOULD CLEANING 2
TRIMMING + INSPECTION 1
GEOMETRICAL INSPECTION 2
NON-DESTRUCTIVE INSPECTION 1

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FINISHING 2
EXPEDITIONS 2
QUALITY INSPECTORS 2
LOGISTIC/WAREHOUSE 4
MAINTENANCE 2
Table 1. Personnel requirements.
3. LAYOUT CONSIDERATIONS
3.1. Plant Layout

Layout of the plant has been defined in the previous WP3 according to the manufacturing
process and operational and logistic requirements.
The plant consists basically of a central logistic corridor for movements of AGVs,
personnel and other logistic vehicles (e.g. forklifts) with lateral operation areas, in which
the manufacturing and testing processes are carried out. The manufacturing areas can be
subdivided into a clean area and a production area.
A warehouse area has been foreseen for delivery and storage of the composite prepeg (in
freezer), auxiliary material and tools. Offices, lockers, rest rooms and meeting areas shall
be also provided for the plant personnel.
Finally, an offices module inside the production area is planned for the heads of the
different areas, inspectors and engineers the working inside the plant.
3.2. Office Layout

Offices shall be designed to fulfill the needs and requirements of the managers,
engineers and administration staff associated to the plant.
The core of all utilities associated with the plant, such as: electrical transformers and
panels, chiller production, data center, compressed air, vacuum and water pumps, etc.
shall be also located in the office building. The office building and plant building shall be
connected through a direct access in the ground floor.
The following distribution has been considered for the office building:
Ground Floor: Technical rooms for utilities, reception hall, medical services and access to
plant.
First Floor: Offices, data center and meeting rooms.

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Roof: Chiller and heating production units.
4. URBANIZATION
The planned urbanization mainly includes the construction of 4 access points to the plant,
roads, parking spaces, sidewalks, green areas, and the access control system.
The access from the main vials of the industrial area is carried out through four points of
entry. Three of them are located on the west side of the plant, and the fourth is located
on the southeast corner of the plant.
It is also planned a total of 120 parking spaces that will be covered with precast shelter.
4.1. Access and Traffic Roads

The access roads to the planted porch consist of 2 lanes, each 3,60 m wide. The total
length of roads is 452 meters.
The roads will have a slope of 2% from the axis of the vial to both sides. The outer
perimeter of the road will be terminated with a precast concrete curb incorporating a
ditch-shaped element for longitudinal drainage.
In the parking sections, a line of valley gutters will be placed on the outside line of the
road. The parking lane will be executed with a slope of 2% towards the axis of the vials.
The pavement planned for the road consists of:
- Asphalt concrete surface, course grading II, thickness 50 mm.
- Asphalt concrete surface, course grading II, thickness 70 mm.
- Aggregate road base course, thickness 250 mm
- Subgrade with CBR ≥ 250 mm.
The total surface of pavement is 5,746 square meters.
4.2. Parking Lanes

The total number of parking spaces projected is 120. They have dimensions of 2.80 x
5.50 m and are located on the north side (40 seats) and west (80 seats).
It is planned to install prefabricated shelter every 2 parking spaces. The dimensions of

the shelter are 5.5x5.6x3 m. The foundation will consist of reinforced concrete footings of
0.15 x 0.30 m.
The pavement planned for the parking lanes is the same as to the roads.
4.3. Sidewalk Areas

Along the entire perimeter of the vials, as well as in the perimeter of the plant is
projected the construction of sidewalks surfaces.

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The sidewalks areas will have a 2% transverse slope for drainage of rainwater towards
the catchbasin network located on the road.
The pavement planned for the road consists of:
- Precast concrete block paving, thickness 75 mm.
- Sand cement mortar bedding, thickness 50 mm.
- Aggregate subbase course, thickness 150 mm
The width of the sidewalks areas is variable according to the area of the urbanization. In
the perimeter of the plant the width is of 2 meters of the side east and south and 4
meters in the east and north side. In the perimeter of the roads, the width is of 1 meter.
4.4. External Lighting

The exterior lighting of the plant consists of a set of luminaires arranged in the outer
perimeter of the plant and roads. LED luminaire of 115 W will be installed on pole of
aluminum of 4 meters of height.
In each luminaire a precast concrete manhole of 0,40 x 0,40 m will be placed for the
connection to the projected electrical network.
The electrical wiring will be installed in PVC pipes placed in a trench along the perimeter
of the plant and the urbanization. The lighting system also comprises the awnings of the
parking lanes. Two 56 W LED lights will be installed on each park position.
4.5. Green Areas

The date palm is a long-lived plant, reaching 200 years of life in areas where it is
traditionally cultivated, such as the project area.
The species has been chosen for its ability to adapt to arid and desert areas with a dry
summer and temperatures of more than 50 degrees. The water needs of the species and
the projected irrigation system has been defined in the annexes of hydrology and
drainage, and irrigation.
5. FOUNDATIONS
A geotechnical and geological survey war carried out on the site proposed for location of
the King Abdul-Aziz City of Science and Technology (KACST) project, consisting mainly
of:
• 9 boreholes.
• 6 test pits.
• 4 soil resistivity tests.

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Figure 2. Location of boreholes and test pits.
The main conclusion of the report of this investigation was the feasibility and suitability of
shallow foundations for hangar type buildings, water tanks and other small buildings with
no special requirements.
5.1. Foundations. Office Building.

All the foundations will be sized according to the premises and recommendations of the
following standards:
• SBC 301 “Structural Requirements for Loading and Forces”.
• SBC 303 “Structural Requirements for Soil and Foundations”.
• SBC 304 “Structural Requirements for Concrete Structures”.
• ACI 318-11 “Building Code Requirements for Structural Concrete”.
Given the results of the geo-technical report mentioned above and in the absence of
restrictive requirements for deformations or anticipation of large loads, the proposal is for
a superficial foundation consisting of isolated reinforced concrete footings under the
planned pillars.

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To ensure support by a layer of terrain with enough load capacity, wells will be dug to an
approximate depth of 1.50 metres and filled with concrete and large rocks to the base of
the footings.
These footings will be joined by tie beams along their entire perimeter, which will serve
as the support of the façade enclosure. The interior footings will be completely isolated
since the low seismic properties of the area do not require more tie requirements.
All the footings must be used to embed the planned pillars and will be calculated for this
purpose to absorb the stresses obtained by calculating the structures.
The ground floor of the office building will have a composite slab resting on the pillars, as
described in Section 1.5.
The loads of equipment that may transmit vibrations, such as air conditioning pumps and
compression equipment, will rest on isolated benches placed over the composite slab
using silent-block damping systems.
Deep foundations are not considered necessary for the offices, initially.
5.2. Foundations. Plant Area.

All the foundations will be sized according to the premises and recommendations of the
following standards:
• SBC 301 “Structural Requirements for Loading and Forces”.
• SBC 303 “Structural Requirements for Soil and Foundations”.
• SBC 304 “Structural Requirements for Concrete Structures”.
• ACI 318-11 “Building Code Requirements for Structural Concrete”.
Given the results of the geotechnical report mentioned above and in the absence of
restrictive requirements for deformations, the proposal is for a superficial foundation
consisting of isolated reinforced concrete footings under the planned pillars.
To ensure support by a layer of terrain with enough load capacity, wells will be dug to an
approximate depth of 2.00 metres and filled with concrete and large rocks to the base of
the footings.
These footings will be joined by tie beams along their entire perimeter, which will serve
as the support of the façade enclosure. The interior footings will be completely isolated
since the low seismic properties of the area do not require more tie requirements.
All the footings must be used to embed the planned pillars and will be calculated for this
purpose to absorb the stresses obtained by calculating the structures. Given the
considerable distance between pillars in the centre of the plants that is necessary to allow
movement of equipment and machinery inside the manufacturing area, the deep
foundation option may be studied if the results of initial sizing of the footings are too
large. In this case, the criteria set forth in Section 4.3 of this document, on Special
Foundations, will be followed.

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The ground floor of the plant will have reinforced concrete flooring that will rest on a
subbase excavated previously to a depth of 1.50 meters and then filled with appropriate
granular soil, levelled and compacted, as shown in the following drawing.
The geotechnical parameters used to size the foundations are a conservative estimate
considering that the plants are located in any position on the plot.
Figure 3. Soil parameters for shallow foundations. Extract from the Geotechnical
Report.
It is understood that these are surface parameters, and it is accepted according to geo-
technical literature that the subgrade reaction modulus k30 can be considered to be
approximately 40,000 kN/m3 for medium density sands under a depth of 1.50 m.
There is still the risk that in the exact location of any of these foundations, the bearing
capacity or deformability of soil would be even worse than the assumed parameter
values. These risks can only be avoided through a more intense geotechnical campaign in
the exact foundation locations. The availability of accurate geotechnical data for the
exact foundation coordinates would probably result in an optimization of the foundations.
5.3. Special Foundations

The corresponding foundations will be built in the production areas of the plant to receive
the specific type of machinery and comply with the requirements of each manufacturer.
The available geotechnical report omits a suitability analysis for the special foundations
that shall support the high technology machines of the plants (e.g. ATL, AFP, Milling
machine), that demand very strict deflection tolerances.
A concept analysis was carried out to establish the most adequate foundation type based
on the available data, concluding that the safest and more economical option would be a
deep foundation system consisting of a concrete slab supported on micropiles.
Foundation Design Requirements
A list with the foundation requirements specification and layout drawings for the
machinery delivered by M. Torres follows:

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Layout Drawing
Code Machine Spec. no.
no.
8173 TPANEX Large EMT-2862493 817380002
8174 ATL Large EMT-2862484 817480002
8175 AFP Large EMT-2864699 817580002
8176 TMILL + TTOOL Large EMT-2864698 817680002
8177 NDI Large EMT- 2864700 817780002
Table 2. Foundation design requirements.
The foundation requirements for the other machines, not provided by M. Torres, shall be
designed in accordance to the manufacturers’ specifications, once this machinery is
accurately defined.
The main Codes, Guides and Norms that affect the foundation design are listed below:
• Load Values, Load Cases and Load Combinations: in accordance with
o Specifications of M. Torres (listed before)
o SBC 301 “Structural Requirements for Loading and Forces”
o ASCE 7-10 “Minimum Design Loads for Buildings and Other Structures”
• Maximum allowable relative deformation: in accordance with
• Concrete Pile Cap / Foundation Slab Design in accordance with:
o SBC 303 Structural Requirements for Soil and Foundations
o SBC 304 Structural Requirements for Concrete Structures
o ACI 318-11 “Building Code Requirements for Structural Concrete”
• Micropile Design: in accordance with
o SBC 303 Structural Requirements for Soil and Foundations
o Publication No. FHWA NHI-05-039 “Micropile Design and Construction

Reference Manual” by the Federal Highway Administration of the U.S.
Department of Transportation

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o “Guía para el proyecto y la ejecución de micropilotes en obras de carretera”

(“Guide to Design and Execution of Micropiles in Road Construction Works”
by the Spanish Ministry of Public Works and Transport).
5.3.1. Plates Inserted and Levelled over Slab

Layup moulds should be positioning on a flat surface within required tolerances in order
to have an accurate layup.
It is then recommended to prepare foundation with plates inserted and levelled to the
right height between all of them.
Attached some pictures. For a better positioning, one plate can have a Positioning point
and 3 plates tear holes.
Layup moulds should be also prepared with corresponding adaption to every plate.
This project does not included Plates on the AFP and ATL machine as parts to be layup
are not defined. Although it is not the best solution, those plates could be done later on.
In that case, holes have to be done in a control area as machines are inside a clean
room.
Figures 4. Plates inserted and labelled over slab.

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6. STRUCTURES
6.1. Office Building

The structure of the office building comprises a steel structure throughout; concrete will
only be used for the composite slabs. It will have a total number of three composite slabs
for the 2 floors, as the first will be implemented as a suspended floor to prevent its
contact with the ground. (ground level floor, upper level floor and upper level roof).
The steel structure will be made up of beams (IPE or HEB type) and HEB-type columns to
be able to support and give global stability to all of the elements and machines on the
roof. In accordance with the following diagrams, the majority of the beams will be from
the IPE range, because as there is no depth limit imposed for the beams, we can achieve
the same inertia with a considerably smaller waste in kilos of rolled steel.
On the roof, the metal profiles, due to their versatility, will be arranged in the required
places to correctly support the various machines that will be installed on the composite
slab.
Figure 1. Arrangement of machines on the roof. Office Building.
All of the columns for the office building will be embedded in their bases on a grid
arranged between them.
The three aforementioned composite slabs are made from a composite slab with a total
depth of 70 mm, a thickness of 1 mm and a 90 mm layer of concrete. It will have
negative and positive reinforcement of φ10c/21 and an electrowelded mesh φ6 150x150.
(The slab will function via lost formwork, as we will also reinforce it lower down on each
one of its grooves). We will try to ensure that these slabs do not exceed a span of 2.5
metres. This is for two reasons: to avoid the need for bracing during the building phase
and to guarantee proper safety conditions under final serviceability conditions.
The geometric and construction design characteristics are as follows:

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Mesh
Heights in mm
Composite slab (e=1 mm)
Figure 6. Slab section.
The final selection of the total slab depth is always made on the premise that the
deflection of the structure in service must be compatible with the perfect working
condition of the building.
6.2. Plant Area

Given the large dimensions of the plants being designed, a structure entirely of steel is
chosen as the optimal solution.
Characteristics:
• In order not to interfere with the workstations and to provide regular availability,
the optimal distance between frames is 6.3 metres. A good separation is therefore
created that complies with all modulation values imposed for the positioning of the
columns. Likewise, the purlins are not an influencing factor in the design of the
plants, as these are rolled profiles IPE220
• There is a total number of two structural joints (J-J’ and N-N’ axes). There will be
three sections with the following lengths:
o Clean Area: 107.1 m.
o Industrial Area: 81.9 m and 64.06 m.

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Figure 7. Location of the two structural joints to be used. Large Plant.
• The floor dimensions between the axes of the end columns are 254.9 metres x
142.8 metres.
• To cover the space, three gantries are created (one for each working area, plus
the space of the corridor) with floor dimensions between axes of 51.5 + 39.8 +
51.5 metres. The corridor has the necessary width to have a foyer so that the
largest parts to be made (35 x 7 metres) can be moved from the industrial area
to the clean area.
51.5 metres 39.8 metres 51.5 metres
Figure 8. Gantries.
• As mentioned above, this analysis corresponds to a frame, whose main

characteristics are presented below:
o Span: 51.5 meters
o Truss thickness at mid-span: 4.80 meters
o Truss thickness at the extreme: 3 meters.

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• As mentioned above, this analysis corresponds to a frame, whose main

characteristics are presented below:
o Span: 39.8 meters
o Truss thickness at mid-span: 4.39 meters
o Truss thickness at the extreme: 3.0 meters.
• For the clean area, which represents the remaining 100 metres of the plant,
everything will be on the same level. The lower chords will have the necessary
profiles to create an internal cubicle, and just as with the external columns, it will
house a maintenance corridor.
• Due to the spatial dimensions of each workstation in the plant, it is necessary to

create the largest possible areas so as not to interfere with them. The work areas
were studied and separations were created in multiples of 6.3 metres (previously
mentioned as the optimal separation). As a more generalised separation between
the main columns, in the central corridor area, 18.9 metres was chosen, although
in two areas (clean area and industrial area), a separation of 25.2 metres was
established.
• Each of these trusses will in turn be supported on a truss that incorporates them
and transfers the load to the columns.
There will be a total of 3 overhead cranes. In the production area there will be two, one
with a lifting capacity of 8 t and another of 16 t. In the clean area there will be a third
with a lifting capacity of 10 t. The overhead cranes will be suspended, via rail beams
under the lower chord of the trusses. In addition, the span of the overhead crane will not
under any circumstances reach the distance between the gantries. In the case of the
Large Plant, the following is proposed:
• Span of 31 metres for the crane with a lifting capacity of 10 t.

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Figure 9. Cranes.
7. ARCHITECTURE
7.1. Roofs and Water-proofing

There are two kind of roof designed:
• A roof panel system
• An inverted walking roof
1. A GABLED NON-TRAFFICABLE ROOF is proposed, with a slope of 7%, placed on the

structure trusses. A system roof insulating sandwich panel will be placed. The panel
will consist of the following elements:
o External side / Trapezoidal Fe. 0,6mm, PUR 50my, RAL to define
o Mineral Wool A1 Acc. EN13501-1, Thickness 150 mm
o Internal side Fe. 0,55mm - Polyester 25 my RAL 9010
o Module width 1000 mm
o U value = 0,24 W/m2K
o Fire Resistance: EI 120 minutes
This system provides the shell with the necessary mechanical, thermal and acoustic
features.
On the ends of the roof, perpendicular to the line of maximum slope, are placed the
interior gutters that collection the water from the entire roof surface, equipped with
the corresponding bowls to channel the water to the downspouts.

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Dynamic joints are proposed between the gutter and the roof panel; these will allow
expansion of the roof panel and guarantee system water tightness, all of which will
be located behind the apron of the main building facade.
Figure 10. Roof details.
2. An INVERTED WALKING ROOF FOR PEDESTRIANS with ceramic tile is proposed. The
slope will be 1%. This roof is consists of the following elements:
o Slope.
o Regulating mortar layer.
o Asphaltic primer.
o Two-layer waterproofing with blow-lamp. Adhered solution. 2.5 mm thicknesses.
o Anti-punching geotextile layer.

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o Thermal insulation. Rigid extruded polystyrene (XPS) foam board. 100 mm

thickness.
o Anti-punching geotextile layer.
o Floor finishing bedded on cement mortar.
7.2. Enclosure, Partitions and Linings
7.2.1. Partitions and Linings

1. The divisions on the first floor in the offices area will be carried out by means of
removable modular partition MOVINORD type M-92, or equivalent, blind, with
profiled view of lacquered steel in the oven, insulation of 55 mm of rock wool, and
double panel of cladding board Of PVC of 13 mm, with a total thickness of 80 mm,
sound insulation 45 dB and RF-60.
2. The partitions of toilets and showers, both on the ground floor and first floor, are
projected through a compact phenolic panel 13 mm thick, moisture resistant, with
polished and bevelled edges, color to choose from by the facultative address, and
bar superior stabilizer of 25x25 mm of aluminum.
3. Demountable partition with visible profiling type M-82, or equivalent, stained glass
with blind base of 880.5mm height of plasterboard panel, with profile in lacquered
steel, double glazed 5/6mm.
4. The outer fence will be a system of free-standing sandwich panels, providing easy
assembly and architectural homogeneity, as well as the necessary thermal and
acoustic characteristics.
The panel consists of the following elements:
• Inner galvanized steel sheet, with a minimum prelacquer 0.6 mm thick.
• A layer of insulation made of incombustible rock wool with a minimum thickness of

150mm and minimum density of 120 Kg/m3.
• An outer galvanized steel sheet, with a minimum prelacquer 0.6 mm thick, special
quality and UV protection.
This facade enclosure is placed on a reinforced concrete wall with an external

thermal insulation composite system and exterior lining. This wall will be
approximately 2.10 meters high and coincide with the height of the external
pedestrian doors.

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Figure 11. Exterior wall detail.
5. The outer plate of the facade is extended at the top, forming the roof apron and
making it continuous.
6. The partitions of toilets and showers, both on the ground floor and first floor, are
projected through a compact phenolic panel 13 mm thick, moisture resistant, with
polished and bevelled edges, color to choose from by the facultative address, and
bar superior stabilizer of 25x25 mm of aluminum.
7. 100mm thickness internal plasterboard wall is used to the small reception hall
located in production area.
7.2.2. Clean Areas Walls and Partitions

1. The proposal for the shell of the clean areas consists in a system of free-standing
sandwich panels lined with easy-to-clean and effective material, airtight, pressure-
resistant, with no cracks or fissures and that does not generate particles that can
affect the manufacturing process taking place within the rooms.
The panel consists of the following elements:

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• Internal smooth sheet with a minimum prelacquer thickness of 0.6mm and plastisol
finish.
• A layer of insulation made of incombustible rock wool with a minimum thickness of

80 mm and minimum density of 120 Kg/m3.
• External smooth sheet with a minimum prelacquer thickness of 0.6mm and plastisol
finish.
2. The horizontal enclosure, made of continuous panels with hidden profiles, will hang
from the main shell of the plant, acting as a false ceiling. This will make it easy to
access for maintenance purpose.
3. The proposal for the pavement is a self-leveling epoxy resin with a very smooth and
bright surface that impedes adherence and accumulation of dirt particles or dust
and favours easy detection of dirty surfaces. Very resistant to the cleaning agents.
7.3. Pavement and False Ceiling
7.3.1. Pavement
1. The more used pavement in the project is a system of a three-layer resin floor-
coating for concrete and similar substrates.
The same type of continuous pavement is projected in the technical rooms of

ground floor, except reception hall and toilets.
2. For wet rooms, both in the ground floor and in the first floor, the pavement is
projected by means of dry pressed earthenware tiles, 20x20cm, for dense traffic,
color to be chosen by the facultative management, received with cement mortar
CEM II / BP 32.5N and M-5 river sand.
7.3.2. False Ceiling

There are three types of false ceiling that differentiate according the uses and occupancy
of the rooms. The most industrial one is used for technical corridors. On the other hand
the finest one shall be provided for offices, halls and waiting areas.
7.4. Carpentry, Glasswork and Metal Works

First of all, because of the size and variety of uses in this project, an important range of
doors are proposed attending to comfort, esthetic qualities and to contribute to safety
and firefighting.
7.4.1. External Doors

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The external doors will be a system of doors industry with specifications for durability and
tightness. The doors have a steel plate substructure and insulation similar to that of the
solution proposed for the facade. They will also have UV protection.
7.4.2. Emergency Doors

Emergency doors consisting of single leaf doors and push bars will be used. These
exterior pedestrian doors must meet the minimum emergency requirements set forth in
firefighting regulations. The protection and insulation properties of the shaped sheeting
of the doors must similar to that of the facade. The minimum dimensions for these doors
will be 1.00 x 2.10 meters.
Taking advantage of the height difference between the roofs, fixed windows will be
placed in the central span for the entry of sunlight.
Figure 12. Pedestrian doors vs truck doors.
7.4.3. Clean Area

For all the doors we choose a double door system, are high-speed roll up doors. These
are air tight with rot-proof special seals, equipped the rooms with a total air tightness
and preserving the overpressure. Equipped with presence detectors and manual opening
in case of power failure.

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The principal door for this clean area for the special parts will be hangar doors, with a
double door system. The minimum width will be 38.00 meters and 5.00 meters height.
The Warehouse access doors will be high-speed roll up doors. Width 3.60 meters and
height 3.00 meters.
The personal doors will be door especially for clean room, flush on both sides of the
panel, allow easy cleaning, durability and high resistance to impacts. Width 1.00 meters
and height 2.10 meters.
Figure 13. Pedestrian doors vs industrial doors.
7.4.4. Windows
Secondly, windows are not prominent figures due to the location and environment. Most
part of them are reserved to the office building but always projected trying to avoid solar
radiation. In addition, glazing shall always be reinforced to thermal insulation and solar
protection. That consist of two glasses separated by a hollow metal spacer filled with
desiccant. The assembly shall be sealed with a double flexible silicone structural seal that
has been approved by the silicone manufacturer, the metal profile manufacturer of the
chassis and the insulating glass manufacturer.
The window scheme will be 6+6/12/5+5 with double glass panes, acoustic and solar
glass protection and a reinforced thermal insulation chamber.

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7.5. Stairs
We propose to place an exterior stairs (see schema, color blue) with metallic structure for
the maintenance of the machines over the roof. This stairs will connect the patio located
over the roof of the ground floor office building with the principal roof of the large plant.
The course of the stairs to access to the roof of the first floor office building and the large
plant for maintenance of the machines over the roof clean areas.
There are three more stairs that connects ground and first floor (see schema, color
orange) and another that is necessary for evacuation (see schema, color yellow).
8. UTILITIES
8.1. General Requirements

Utility main connections must be installed when urban development takes place.
The utility drawings included the proposed location of utility main connections to take
account during the urban development design.
8.2. Plumbing
The design of the potable water supply will be done so as to comply with the
requirements included in the following standards:
• Saudi Building Code Part 701 – Sanitary.
• International Plumbing Code.
The water supply would be provided from a main supply connection for a general
distribution pipeline located as shown in the figure.

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Figure 14. Water supply connection.
This main distribution pipeline should be at least of 110 mm and 30 m.c.a. This general
will be on a ring for the factory and the offices. The demand for general use will be
determined using this table according with the Saudi Building Code Part 701.
Fixture Flow Cold water (l/s) Flow Warm water (l/s)
Lavatory 0.125 0.080
Shower 0.200 0.080
Sink 0.100 0.100
Urinal 0.900 -
Water closet 0.360 -
HVAC 2.350 -
Refrigeration towers 12.00 -

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Fire deposit 1.00 -
NDI 0.850 -
Table 3. Water flows.
The hot water supply system will be designed based on the use of Electrical Water
Heaters for each zone that requires hot water.
The pipe material will be PE for cold water and PE for hot water. Water hammer arrestors
will be provided at desired location on both cold and hot water lines to absorb eventual
shock preventing damaged on pipe, especially on pipe joints.
8.3. Hydrology and Storm Drainage System

The fundamental data used are, in accordance with the Saudi Building Code (SBC) of the
Saudi Building Code National Committee (SBCNC), chapter 6, entitled Storm Drainage
Systems. According to the content of this chapter, weather data in the area have been
taken as collected at Riyadh Airport by the Ministry of Defense and Aviation from 1985 to
2010.
The designed drainage system includes the necessary elements for the reception,
transport, pumping, storage of rainwater collected on the surface of the plant and the
urbanization zone.
The system has been designed with the objective of maximizing the use of rainwater, so
that the plant can independently cover the total irrigation water needs of the
urbanization.
With this objective has been projected a tank of reinforced concrete of 1,275 cubic
meters of capacity and an interior dimensions of 15 x 25 x 3.4 meters. To this tank will
be pumped a certain amount of the collected rainwater, to be used as water of irrigation
in the urbanization.
The building object of the project consists in the longitudinal sense of 3 modules
constructed by means of metallic structure. The 3 modules have been designed with a
gable deck with a slope of 7%. The total surface area of the deck is approximately
36,664 square meters.
The water coming from the leaders will be led to 12 manhole of 0.50 x 0.50 m located in
the outer perimeter of the plant. From there you will be led through some PVC DN 250
SN 8 collectors to four 1.0 x 1.0 x 3.0 m reinforced concrete manhole located in the
corner of the plant. From there, rainwater will be pumped to the storage tank located on
the east side of the plant.
The drainage of the urbanization area consists of a reinforced concrete catchbasins

system to which a system of buried PVC collectors will be connected that will lead the

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water up to the four pump manhole of the plant. The collectors will be located in trenches
on the perimeter sidewalk of the plant.
8.4. Irrigation System

The rainwater drainage system of the plant aims to achieve water storage to cover the
needs of irrigation water for a full year.
The estimated irrigation water requirements for trees are initially estimated. The number
and class of trees provided is:
- Date palm (Phoenix dactylifera L.)

- 23 units.
The construction of a reinforced concrete tank with a useful storage volume of 1,275 m³
has been projected. The interior dimensions of the tank are 15 x 25 x 3.40 m. Next to
the tank will be a pump room with interior dimensions of 5 x 10 m. The thickness of the
walls and the top face is 0.3 m, and the supporting hearth has a thickness of 0.40 m.
The irrigation system consists of a pump equipment with a power of 1.5 KW, which
supplies a flow of 8 m3/h to the different areas of palm trees in the urbanization. The
irrigation network consists of a system of PEHD pipes buried in trenches and divided into
several sectors according to the location of the groups of palm trees.
8.5. Sanitary Drainage and Waste Water System

The sanitary drainage system will be designed as a single network for the Large Plant,
i.e. waste and soil will be collected in the same pipe. The vent system will be a network
connected with the sanitary stacks. The vent will use P-traps to connect the vent system
with the fixtures. The material used for sanitary drainage, waste water system and vent
system is PVC.
The design of the drainage system is in accordance with the Saudi Building Code, 701
sanitary chapter 4. The math method is the drainage fixture unit value of table 4.9.1. The
minimum size of trap will use to connect the fixture to the branch.
The pipe size is according the table 4.10.1 (1) and 4.10.1 (2).
The vent system is designed following the Saudi Building Code, 701 sanitary chapter 5.
The drainage system design was done to minimize the building drain slope at 1%
The vent system design was done to have a stack from the building drain to the open air.
8.6. Compressed Air System

A compressed air system is provided for the plant.
The compressed air system generation is formed by two air compressors, filter, oil and
water separator, a vessel, and the pipe distribution system.

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The system has two similar air compressor with variable frequency drive. The air cooler
and air dryer are incorporated to air compressor.
Al the manual tool intake or machine intake are provided with pressure redactor to
control the pressure inlet supply.
The next table show the demand conditions of the different intake:
Production Process Compressed Air Demand
TPANEX 6 bar, 2500 LN/min, 1''
ATL 6 bar, 700 LN/min, 3/4''
AFP 6 bar, 4000 LN/min, 1 1/2''
TMILL + TTOOL 6 bar, 16500 LN/min, 1''
NDI 6 bar, 2400 LN/min, 1''
Large Autoclave 6 bar, 6000 LN/min, 1”
Small Autoclave 6 bar, 1200 LN/min, 1”
Manual tool intake 6 bar, 00 LN/min, 1/2”
Table 4. Compressed air requirements.
8.7. Vacuum System

A vacuum system is provided for the plant.
The vacuum system is formed by two vacuum pumps, two filters, a vessel and the pipe
distribution system.
The system has two similar vacuum pumps with variable frequency drive.
All the vacuum intake all for manual tool with a demand of: -0.8 bar, 800 LN/min, 1/2''
8.8. HVAC
This document establishes the mechanical design criteria for the plant. It includes the
chilled water production station, ventilating and air conditioning mechanical equipment
and systems.
HVAC system is designed in order to:
- Maintain specified temperature conditions in the clean and production areas,

taking into account the outside conditions, the numbers of occupants and the heat
gain from equipment and lighting.

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- Maintain specified humidity conditions in the clean and production areas.
- Supply outside fresh air for ventilation requirement.
- Achieve overpressure to prevent air infiltration.
- Filtrate air to eliminate dust and contaminants.
- Save energy.
The main following codes and standards have been used in the present discipline:
- M 501 Mechanical Saudi Code
- Ashrae. Handbook – HVAC systems and equipment
- Ashrae. Handbook of Fundamentals
- Ashrae. Applications
8.8.1. Design Criteria

Outside Conditions.
Calculations have been carried out taking into account the outside conditions specified in
Chapter 14 of Ashrae Climatic Design Information for Riyadh OBs (OAP):
Location: Riyadh Obs (OAP)
Altitude (m): 620
Latitude: 25º 0’ 0”N
Longitude: 46º 0’ 0”E
Summer percentile: 0,4% 1% 2%
Dry temperature (°C): 44,2 43,8 42,9
Wet temperature (°C): 18,7 18,5 18,2
Winter percentile: 99,6% 99,0%
Dry temperature (°C): 5,9 7,2
U values.
The coefficients of heat transfer (U) taken into consideration are as follows:
- Exposed roof U-value: 0,22 W/m2K

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- Exposed wall U-value: 0,27 W/m2K
- Floor U-value: 0,2 W/m2K
- Glazed windows U-value: 2,5 W/m2K and SF: 0,3
- Interior partitions: 0,45 W/m2K
Temperature and humidity conditions.
For the peak outside ambient conditions, the HVAC system has been designed to achieve
the following indoor conditions:
Temperature Humidity ratio

Area
Summer Winter Summer Winter
Clean area 22ºC±2ºC 22ºC±2ºC 40%±10% 22ºC±2ºC
Production area 24ºC±4ºC 22ºC±4ºC 50%±20% 50%±20%
Sanitary area 24ºC±4ºC 22ºC±4ºC 50%±20% 50%±20%
Offices 24ºC±4ºC 22ºC±4ºC 50%±20% 50%±20%
Table 5. Temperature and humidity conditions.
Infiltration.
Based on Ashrae SSPC-90.1 Envelope Subcommittee, infiltration rate used to calculate

the thermal loads is 0,68 m3/h·m2 for opaque doors and loading dock doors for the
Production Room.
Infiltration Total
Production room Dimensions (m) Units rate infiltration
(m3/h·m2) rate (m3/h)
Loading dock
5x5 1 0,68 17
doors
Opaque doors 1,73x2 15 0,68 35,3
Table 6. Infiltrations.
The infiltration rate considered for the Clean Room is zero.
Ventilation requirements.

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- Clean area: 2 air changes per hour. A positive pressure of 5 Pa shall be

maintained with respect to the adjacent areas. The maximum particle
concentration in this area shall be 29.300 particles per m3 of air.
- Production area: 0,85 l/s·m2
For the offices module and the sanitary area, the following fresh air ventilation rates have
been considered according the Saudi Code:
Room/area Occupancy Ventilation rate
Toilets - 36 l/s per WC
Shower rooms - 10 l/s per shower head
Locker rooms - 2,6 l/s per m2
Dining rooms 75 pers/100 m2 10 l/s per person
Warehouse - 0,26 l/s per m2
Offices 7 pers/100 m2 10 l/s per person
Conference rooms 53 pers/100 m2 10 l/s per person
Reception areas 65 pers/100 m2 7,5 l/s per person
Telecommunication centers 64 pers/100 m2 10 l/s per person
Patient room 10 pers/100 m2 12 l/s per person
Table 7. Fresh air ventilation rates.
Air filtration shall meet, as a minimum, the requirements listed in ASHRAE Applications
and ASHRAE Systems and Equipment Handbooks.
In case of outside air equal to or greater than 30% of total supply air or having an
outside air flow rate of 2400 l/s or greater, an approved sand trap filter shall be provided
and located ahead of all ductwork.
Internal lighting and heat gain to air conditioned spaces.
Plant
The ratio of 5W/m2 has been adopted for internal lighting.
The main heat gains are coming from the equipment used in the composite fabrication
processes. It has been considered 25 W/m2.
Offices

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The ratio of 5W/m2 has been adopted for internal lighting.
Heat gain from equipment: 3W/m2.
Design calculation safety factor.
- Cooling load: 5%
- Heating load: 5%
8.8.2. Solution
The results obtained from the load calculations are listed in the HVAC Annex.
AHUS.
The air-handling units planned in the different spaces are the following:
- Clean area: AHU-CL1, AHU-CL2, AHU-CL3, AHU-CL4, AHU-CL5, AHU-CL6, AHU-
CL7 and AHU-CL8
- Production area: AHU-PR9, AHU-PR10, AHU-PR11, AHU-PR12, AHU-PR13 and
AHU-PR14
- Warehouse : AHU-WH1
- Ventilation for offices module : AHU-FA1
- Sanitary area : AHU-FA2
- Ventilation for offices building : AHU-FA3 and AHU-FA4.

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Manufacturing Plants for Composite Aeronautical Components
Table 8. Air handling units characteristics.

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Fresh air shall be filtered to remove sand and dust particulate materials, through sand
trap louvers before entering the AHU. Fresh airwill be treated by AHU’s with heat
recovery wheel or cross flow plate. The AHUs supplying the clean area shall be equipped
with HEPA filter H13.
These AHUs shall be full modulating 2-way valves in order to reduce energy
consumption.
Motors of the components shall be with variable speed/frequency drive (VSD/VFD).
THERMAL POWER PLANT.
The thermal load required in the plant taking into account the cooling and heating
capacities of the AHUs in the previous table is the following:
Total cooling load Total heating

(KW) load (KW)
Clean area 2.938 1.977
Production area 1.394 664
Table 9. Thermal power plant.
The thermal plant that supplying the clean area is equipped by the elements listed below:
- 6 heat pumps (one of them planned for redundant operation in case of failure of
any of the units). Primary circuit works with constant flow rate. These pumps are
contained in the heat pumps
Cooling capacity Heating capacity

(KW) (KW)
Heat pump clean area 659* 711

*Cooling capacity considering that the heat pump is working at 44,2ºC.
- 4 secondary circuits working with variable flow rate:
C1: supplying AHU-CL1 and AHU-CL2

Pumps are planned in the pump room of the ground floor of the offices building.
The thermal plant that supplying the production area is equipped by the elements listed
below:

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- 3 heat pumps. Primary circuit works with constant flow rate. These pumps are
contained in the heat pumps
Cooling capacity Heating capacity

(KW) (KW)
Heat pump production

522* 563
area
*Cooling capacity considering that the heat pump is working at 44,2ºC.
- 2 secondary circuits working with variable flow rate:
C5: supplying AHU-FA4, AHU-FA1, AHU-PR9, AHU-PR10 and AHU-PR11
C6: supplying AHU-WH1, AHU-FA3, AHU-PR12, AHU-PR13, AHU-PR14 and

AHU-FA2
Pumps are planned in the pump room of the ground floor of the offices building.
Regarding cooled/heated water distribution, it is planned:
- Manifold and pipeline: It consists on a 2 pipes installation which serve as the
heating and cooling pipework. The entire pipe network will be made of black steel.
They will be insulated according the standards. Finally, pipes and insulation will be
covered with aluminum sheet.
- The following is the maximum and minimum pipework velocities that shall be used
as well as the limiting pipework pressure drop:
Minimum
Maximum Maximum
pipework velocity Maximum
pipework pipework
pipework
velocity in plant velocity in false
To Φ From Φ pressure drop
rooms ceilings
50mm 50mm
0,75 1,25
2,5 m/s 1,5 m/s 40 mmca/m
m/s m/s
- Valves:
 Shut-off valves: ball valves will be used for diameters up to 1 1/2”;
for diameters over 1 1/2” they will be butterfly valves with a
stainless steel disc; for diameters up to 5” they will be of the
scissors type and wheel valves will be used for diameters larger
than 5”, to facilitate manual rotation.
 Filters: Y-shaped with a stainless steel basket. These are installed
upstream from the pumps.
 Axial expansion compensator.

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 Air vents: they will be installed at the highest points of the circuits.
They will be automatic and adjustable.
Finally, the air will be distributed through round or rectangular air supply and return
ductwork made of galvanised steel plate.
The maximum drop of pressure considered in the ducting system is 0,8 Pa/m and the
maximum velocity considered is as follows:
Main duct supply 7 m/s
Main duct return 6 m/s
Branch duct supply 4 m/s
Branch duct return 3 m/s
Direct Expansion System.
Offices building and offices module are provided with a VRV system in order to adjust the
amount of refrigerant flowing to the multiple evaporators (indoor units), enabling the use
of many evaporators of differing capacities connected to a single condensing unit.
The following three different VRV are planned:
Offices building
Offices
Electrical module
Left area Right area
rooms
Cooling capacity (KW) 66,76 60,32 150,0 33,5
Heating capacity (KW) 75,25 67,64 - 37,5
Consumption 21,2 18,6 44,1 10,2
The set of condenser and evaporator units are designed for the single offices listed
below:
- Reception production area
- Testing area
- Production control area
- Logistic warehouse and maintenance
- Centralized data processing (inside the offices building)
8.9. Fire protection

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The compliance with fire protection measures of a composite aeronautic component

manufacturing plant located in Riyadh, Kingdom of Saudi Arabia, has been described in
the fire protection annex.
The composite aeronautic component manufacturing plant will be designed according to

the Saudi Building Code Fire Protection Requirements (SBC 801) as well as any others
referenced therein.
8.9.1. Fire Protection Systems

The fire protection systems for each building are:
Offices and warehouses building.
• Automatic sprinkler system, except in low voltage power room, generator room
and medium voltage power room.
• Potable fire extinguisher, only in special hazard rooms of office area (business
group B).
• Clean agent fire extinguishing system, only in centralized data processing room.
• Automatic smoke detection only in low voltage power room, generator room and
medium voltage power room.
• Fire alarm system (public address system).
Clean room building.
• Automatic sprinkler system, except in production control area, a group B

occupancy.
• Potable fire extinguisher.
• Clean agent fire extinguishing system, only in limited lifetime material warehouse.
• Smoke and heat vents (mechanical smoke exhaust).
Production building.
• Automatic sprinkler system, except in testing area, a group B occupancy.
• Smoke and heat vents.
Painting building.
• Automatic sprinkler system.

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8.10. Electrical Installations
8.10.1. Applicable Standards

The low voltage electrical installation will be according to the following applicable
standard:
• Saudi Building Code Electrical Requirement (SBC 401)
• IEC 60364 (Electrical Installations of Building)

The following design criteria will be considered to decide the dimensions of the
installation:
• Voltage: 220/400 (V)
• Frequency: 60 (Hz)
• Ground connections: TN-S
• Established voltage drop: <4% between the source of the installation and the
receivers
• Cos phi: 0.8
8.10.3. Foreseeable Power

The power for the plant will be calculated from the sum of loads required by the various
plant services and installations:
• Lighting
• Power
• Air conditioning and ventilation
• Machinery to be installed at each work station
• Other services, installations and/or equipment

Next table shows a summary about the power loads considered for the balance power.
LOADS POWER (kW)

JDB001 62,42
AHU-FA4 SUPPLY 2,25
AHU-FA4 RETURN 2,20
VRV LEFT AREA 12,00
AHU-FA3 SUPPLY 0,96

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LOADS POWER (kW)

AHU-FA3 RETURN 1,15
VRV RIGHT AREA 12,00
AHU-WH1 SUPPLY 1,63
AHU-WH1 RETURN 2,65
EXAHUST FAN 15,00
CHILLER 7 302,10
CHILLER 1 338,29
CHILLER 2 338,29
CHILLER 8 302,10
CHILLER 3 338,29
CHILLER 4 338,29
CHILLER 5 338,29
CHILLER 6 338,29
CHILLER 9 302,10
JDB002 92,97
AHU-CL1 SUPPLY 11,43
AHU-CL1 RETURN 18,12
JDB007 73,85
JDB003 76,76
JDB008 94,43
JDB004 90,20
AHU-PR9 SUPPY 8,72
AHU-PR9 RETURN 15,38
AHU-PR10 SUPPLY 8,72

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LOADS POWER (kW)

JDB005 76,69
JDB009 62,49
VRV WAREHOUSE 5,00
VRV BATHROOMS 10,00
AHU-FA2 SUPPLY 5,00
AHU-FA2 RETURN 5,00
VRV RESTING ROO 15,00
AHU-FA1 SUPPLY 5,00
AHU-FA1 RETURN 5,00
BUSBAR 1 301,51
BUSBAR 2 51,34
BUSBAR 3 101,15
BUSBAR 4 526,39
BUSBAR 5 44,00
BUSBAR 6 95,10
DB-OFFICES 70,20
JDB001 40,18
DB IRRIGATION 2,00
DB-FIRE PROTEC 10,00
DB- OUT. LIGHT. 23,40
DB VACUM ROOM 65,80
JDB002 48,00
DB RECEPTION 16,07
DB-MAINTENANCE 8,59
DB-LV ROOM 8,59
DB-CHILLER ROOM 88,75
DB-GENERATOR 148,67
TOTAL LOADS 5719,53 (KW)
Table 10. Balance Power
In order to supply this load value, the electrical substation shall be equipped with 4

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transformer units 1.600 kVA each one.

On the other hand, in the case of the electrical supply for autoclave equipment’s, an
independent electrical substation shall be installed near to the autoclave area. This electrical
substation shall have an exclusive use for autoclave equipment’s.
8.10.4. Description of the Low Voltage Electrical Installation

The low voltage electrical installation will begin at the low voltage terminals in the
transformers located at the electrical substation.
The connection between these transformers and the new Main Distribution Board
(hereinafter, MDB) will be made using prefabricated busbar trunking. The illustration
below provides a detailed view of the proposed solution.
Figure 15. Connection between the Transformer and the MDB.
The MDB supplies the various DBs distributed throughout the plant and at the base of the
main loads.
DBs will be provided for each of the main work stations in the plant, as well as main
boards used to supply the services in the main work areas: clean area, production and
offices.
The interconnection between the MDB and the DBs will be done using a prefabricated
busbar trunking systems. Specifically, six busbar trunking systems shall be installed in
order to supply the loads located in the clean and production areas. Four units shall be
use for power loads (Busbars 1, 2, 3 and 4), and 2 units shall be use for lighting loads
(busbar 5 and 6).
After reaching the DB or receiver, a perforated cable tray will drop to the unit. The
illustration below provides a detailed view of the proposed solution.

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Figure 16. MDB - DB connection system.
A circuit breaker will be installed between the prefabricated busbar trunking and the drop
to the receiver, as shown in the illustration below. These breakers will be motorized in
order to can control its state in remoted way.
Figure 17. Prefabricated distribution system and cabling
The electrical supply or circuit lines will be channelled from the DBs to the various
receivers. This will pass through trenches, trays or pipes, depending on each case.
All electrical wiring will have the following characteristics:
• Conductor: Copper
• Insulation: XLPE
• Outer sheath: PVC
• Halogen-free and low opacity.
• Flame retardant.
• Multi-pole conductors will be used in sections up to 25 mm².

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• Over 16 mm² single-pole conductors will be used.
The trays will be metallic, perforated and galvanized in sendzimir. Solid metallic trays will
be used to supply external equipment; these will be have covers to close the duct.
8.11. Interior Lighting
8.11.1. Applicable Standards

The interior lighting will be defined according to the following applicable standard:
• Saudi Standard: Code for lighting of indoor work places
• Code for lighting: CIBSE Society of Light & Lighting in UK

The interior lighting that is installed must guarantee the levels of lighting and parameters
set forth in the corresponding standards.
Two different plant environments are considered in the study:
• Clean area: 750 lux.
• Production: 500 lux.
• Corridors: 300 lux.
Figure 18. Lux levels in the plant.
In the case of the offices the levels of work lighting will be as follows:
• Work stations: 500 lux.

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• Meeting rooms: 500 lux.
• Rest rooms/Changing rooms: 200 lux.
• Archives: 200 lux.
• Corridors/Walkways: 150 lux.
• Utility rooms and auxiliary rooms: 300 lux.
8.11.3. Description of the installation

The type of light fixtures proposed for the main areas in the plant are listed below.
• General lighting in the Production Area.
Figure 19. Industrial light fixtures for areas with high ceilings.
• General lighting in the Clean Area.
Figure 20. Industrial light fixtures for clean area.
• Technical Room lighting.

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Figure 21. Airtight light fixtures.
• Module light fixtures for offices and areas used by staff.
Figure 22. Ceiling-embedded light fixtures.
The lighting system will be switched on and off by areas and uses, as follows:
• Offices, rooms and archives: Manual push-button switches.
• Rest rooms, corridors and common areas: Presence detection lighting system.
• Clean area and production area: On/Off switching from the central control post
• Outdoors: On/Off switching from the central control post
On/Off switching will be managed from a control system that can be easily integrated
with the building management system.
8.12. Ground Connection and Lightning Rod Network

The following differentiated ground connections are proposed:
• Ground connection systems for neutral cables from the transformer in the new
transformation centre.
• A general and structural ground connection protection system in the new building.

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The general ground connections will consists of a perimeter mesh network comprised by
a bare copper conductor 50 mm2 buried at a depth of 0.8 metres and copper-plated steel
pikes measuring 2 m, with shunts on the various ducts for subsequent grounding of
metal parts. Cadweld type exothermic welding will be used for attachment to the pillars.
A rectangular low voltage ground connection with a bare copper conductor and will be
placed in the new transformation centre for the neutral cabling of the transformer and a
separate medium voltage rectangular ground connection will be placed for medium
voltage fittings.
The grounding network of the lightning rods will be connected to the general grounding
system of the building to prevent generation of hazardous sparks and through currents.
A ground connection will be placed for each downspout, protecting the last three metres
with a metal pipe equipped with a system to disconnect the ground connection to
measure resistance.
8.13. Communications Systems

A communication voice and data system shall be provided based on a Structure Cabling
System. The system is to follow a hierarchical star topology. The design of the Structured
Cabling System will meet the following applicable standards:
• ISO/IEC 11801: Generic Cabling for Customer Premises.
• TIA/EIA 568-B: Commercial Building Telecommunications Cabling Standard.
• TIA/EIA 568-C: Commercial Building Telecommunications Cabling Standard.
• TIA/EIA 568-D: Commercial Building Telecommunications Cabling Standard.
• Saudi Building Codes.
The proposed data network shall provide a complete functional LAN system including but
not limited to Data cabinets, switches, Fiber/UTP patch panels and all other data
equipment.
The Category 6A / Class E portion of the cabling system shall comply with the proposed
channel performance requirements of the latest revision of ISO/IEC 11801 2nd Edition,
Amendment 2.2:2010 “Performance Specifications for 4-pair 100 Ohm Category 6A /
Class E Cabling”.

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Figure 23. Communication – Voice and data network general architecture.
Structured Cabling system.
The Voice and Data system will comprise the following subsystems:
• Telecommunication rooms.
• Backbone cabling.
• Horizontal cabling system.
• Cableways.
Telecommunications room.
Telecommunications rooms provide a common access point for backbone and building
pathways and may contain cabling used for cross-connection.
The main telecommunication room (MER) is located in the Centralized Data Processing
Room, in the second floor of the offices. MER will be the main Data room, where the main
data cabinets will be located.
The provider telecommunication room (PTR) will be also located in the same Centralized
Data Processing Room. The external data/voice networks and Internet connection will be
connected here.

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Secondary data rooms (SER) are located in the plant:
- D2: Autoclave control office.
- D3: Production control area.
These communication cabinets will be 42U racks, dimensions 800x800 mm, with glass
door anchored by screws, back door profiles 19" front and rear lock by key, removable
side panels, lids vertical. These racks will have strips 19 " with 2 x 8 schuko sockets
without switch 1U and grommets 19" 1U. Patch panels consist of 24 RJ-45 ports, Cat.6A.
The patch cords are UTP Cat6A, flexible with removable protective of 3 meters.
Due to distances, other 5 wallmount 12U 19” rack cabinets are installed:
- D4: next to TPANEX FACILITIES ROOM.
- D5: in WAREHOUSE OFFICE.
- D6: next to TRUCK LOADING.
- D7: next to FINAL PROCESS TOOL.
- D8: in Office staff entrance Control room.

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MER RACKS
8 Way unswitched PDU with Surge

Protection
TELEPHONE PANEL
Telephone Panel 50RJ45 cat3 1U
Cable distribution panel 1U
24 Fiber patch panel SC

1 5 9 13 17 21 1 5 9 13 17 21
4 8 12 16 20 24 4 8 12 16 20 24
1 5 9 13 17 21 1 5 9 13 17 21
4 8 12 16 20 24 4 8 12 16 20 24
1
4
4
5
5
8
8
9
9
13
12
13
12
17
16
17
16
21
20
21
20
24
24
1
1
4
4
5
5
8
8
9
9
13
12
13
12
17
16
17
16
21
20
21
20
24
24
24 RJ-45 cat6A patchpanel
Stackable Switch 24ports giga +

4x 10giga fiber
Wireless controller
2 x 42U rack including each:
- 2 x PDU
- 1 x telephone panel 50 RJ-45
- 9 x cable distribution
- 2 x fiber patchpanel
- 6 x patchpanel
- 6 x switches
- 1 wireless controller (only in one rack)
Figure 24. Communication – MER details.

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SER D2
8 Way unswitched Schuko Power

Distribution Unit with Surge Protection
TELEPHONE PANEL

1 5 9 13 17 21
4 8 12 16 20 24
1 5 9 13 17 21
4 8 12 16 20 24

4x 10giga fiber
1 x 42U rack including:
- 2 x PDU
- 5 x patchpanel
- 5 x switches
Figure 25. Communication – D2 details.

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SER D3

TELEPHONE PANEL

1 5 9 13 17 21
4 8 12 16 20 24
1 5 9 13 17 21
4 8 12 16 20 24

4x 10giga fiber
- 2 x PDU
- 2 x patchpanel
- 2 x switches

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Access D4, D6, D7, D8

1
4
5
5
8
9
9
13
12
13
17
16
17
21
20
21
24
4 8 12 16 20 24

4x 10giga fiber
- 1 x PDU
- 1 x patchpanel
- 1 x switches
Figure 27. Communication – D4, D6, D7, D8 details.

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Access D5


1 5 9 13 17 21

4 8 12 16 20 24
1 5 9 13 17 21
4 8 12 16 20 24
4x 10giga fiber
- 1 x PDU
- 2 x patchpanel
- 2 x switches
Backbone cabling.
Backbone cabling is the portion of structured cabling system that provides

interconnections between entrance facilities and communications rack cabinets, and
between buildings.
Telecommunications cabinets shall be connected to MER by providing two 12-cores single

mode fiber optic cables in a mesh topology.
Between the MER and each SER (including MER/SER) a telephony backbone is provided.
The copper backbone shall be built up with category 3 multipair cabling. Each SER needs
to be provided with a 50 pair backbone, mounted on both sides on 50-fold RJ-45 patch
panels. Per patch panel one cable management panel needs to be taken into account.

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Plant
D4 2 x 12FO D6
D2 2 x 12FO
access access
SER
Offices
2 x 12FO
D1 D1 50 pairs 2 x 12FO
PROVIDER MER 2 x 12FO
IT provider
50 pairs
D5 D7
2 x 12FO D3 2 x 12FO
access access
SER
2 x 12FO
D8
access
Office staff entrance

Control room
Figure 29. Communication – Backbone scheme.
Horizontal cabling system.
Horizontal cabling includes horizontal cable, telecommunications outlet/connectors in the

work area, mechanical terminations and patch cords or jumpers located in data cabinets.
The horizontal cable length extends from the rack cabinet to the telecommunications
outlet/connector in the work area. The maximum horizontal cable length shall be 90 m
(295 ft). The length of the jumpers and patch cords that connect horizontal cabling with
equipment or backbone cabling, should not exceed 5 m (16 ft).
All cabling shall conform the Category 6A standard. All cables shall be UTP or F/UTP.
Telecommunications outlets shall consist in RJ-45 connector category 6A at least.
Depicted in the table below are the outlets sizing criteria:
Location Number of outlets
Offices where offices desks are defined 2 outlets per office desk (voice and
data)
Offices (General) 2 outlets per 10/m2 (voice and data)

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Location Number of outlets
Meeting Rooms 6 outlets (voice and data)
Warehouses 4 outlets (voice and data)
Stores 2 outlets (voice and data)
Other working areas 2 outlets (voice and data)
CCTV and ACS 1 outlet per camera or access

controller.
Fire alarm panel 1 outlet
Table 11. Outlets sizing criteria.
Cableways.
Telecommunications cables shall be installed preferably in galvanized steel trays separate

from electrical power installations. Data must not be allowed to run side by side with
electrical cables unless separated by a distance of 50 mm plus an earthed metal fillet.
Cable trays shall be installed along the sides of the plant at a proper height to not
interfere with the works to be done in the plant.
Cable trays shall be placed inside the false ceiling in offices areas.
Cables should be enclosed within telecom conduits or trunking where exposed or in

conduits embedded in flooring.
Telephone system.
Telephone system shall be a Voice Over IP (VOIP) telephone system.
Connection of telephones shall be done via communication outlets, in offices workstations

shall be connected to an internal switch build in the IP-phone. IP-phones not used in
combination with workstations shall not be equipped with an internal switch.
PABX is not included in the scope of this Project.
In addition, it is proposed a 50 pairs telephone cable between data cabinets for dedicated
telephone lines, i.e. lift, fire alarm panel, etc.
Switches.
Stackable switches are provided considering that the data room will have switches level
4, Gigabit Ethernet link with 4 x 10Gigabit fiber optics links.
The design has been based on standard Ethernet switches providing 10/100/1000Base-T
ports for servers and high end users. The switches shall be linked together with a fibre-
optic link cable allowing a through put of 10Gbps between the core switches.

58 of 66
WLAN controller and access points.
The office building is provided with a WIFI network that coverages all desks and meeting
rooms. The solution is managed by a wireless gigabit controller installed in MER.
Wireless access point (AP) are dual band (2,4 and 5Ghz) with a maximum throughput of
1300Mbps. All AC are installed in the ceiling in the indicated locations:
Centralized Data Processing Room

(MER D1)
WLAN controller
Switches
Gigabit
AP AP AP AP AP AP
W01 W02 W03 W04 W05 W06

Reception hall Corridor A Administration Corridor B Engineers Woman workspace
Wireless phone Laptop
Figure 30. Communication – Wireless.
8.14. CCTV and Access Control System

A complete Security shall be provided, consisting in an Access Control System and CCTV
System.

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Figure 31. CCTV and Access Control System.

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Network Video Recorder. 2U. 32TB

storage up to 128 IP cameras.
NVR
ACCESS CONTROL CCTV Server with management

SERVER
software for camera system
CCTV
SERVER
Access control server with

management software for ACS system.
Figure 32. Security rack.
The doors that will be dedicated for staff Access to plant and offices are shown in the
image below:
Figure 33. Doors for Staff Access.

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Access Control System.
A complete Access Control System (ACS) shall be provided, consisting in:
• Access Controller.
• Card Readers: magnetic or contactless (NFC or RFID).
• Equipment for door opening/closing: magnetic sensor, magnetic lock, etc.
• Workstation for control and monitoring of ACS.
ACS controller shall be connected to LAN using data outlets and cat6A cables.
Figure 34. General controlled door equipment.
Emergency door shall be equiped with a magnetic door sensor in order to detect any door
opening. An alarm shall be generated in case a door opening without fire alarm active.
Additionally, a biometric system could be included (fingerprint) to control the access to

particularly sensitive areas. The ACS system could be included or integrated in machines
to control their use by authorized staff.
CCTV System.

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A complete IP-based videosurveillance system shall be provided using IP-cameras, data

switch with Power over Ethernet (PoE) capability, computer workstation with video
management software and enough Storage and screens for monitoring.
CCTV System will comprise:
• IP-CCTV Cameras.
• Supports for camera installing.
• Network video recorders.
• Workstation for control and monitoring of CCTV System.
IP cameras shall cover entrances to the plant and offices, technical rooms and corridors
and provide a general view of clean and production areas and specific locals or machines
as required.
Cameras will be IP fixed suitable for use in indoor or outdoor.
IP Cameras shall be connected to LAN using data outlets and cat 6A cables.
Images of cameras shall be recorded in digital HD format (for example mpeg4, H.264)
and saved on hard disk recorders for configurable time. These network video recorders
shall be located in data cabinets in the MER.
CCTV Control and Monitoring will be done in the Control Room located in the second floor
of offices. The video surveillance system shall be fully integrated with the access control
system opening the opportunity to set predefined camera positions on access controlled
doors to detect an unauthorized access.
All controlled doors and emergency door shall have a CCTV camera.
8.15. Control System

A high-level control integration is proposed:
Main low voltage boxes: consumption monitoring, alarms and faults
• HVAC: start / stop, setpoint temperatures, status, alarms and faults
• Air pressure: control of the status of pressurization equipment, alarms and faults.
• Fire detection: state control switchboards, alarms and faults.
• Firefighting (water and clean agent): control of tank levels, state control of
pumping units, alarms and faults.
To control all plants installations it is proposed to make low-level connections with

structured wiring and MODBUS. In any case if the machinery requires other wiring
(serial, Profibus, CAN, etc.) it will be provided for this service and the corresponding
auxiliary as Ethernet or control and alarm elements for Health and Safety (laser barriers,
visual alarms and acoustic and CCTV for monitoring the production process.
All control signals are included in the calculations document.

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The SCADA server is located in the same rack than the security system in the centralized
processing data room. A client is installed in the control room.
D1
SECURITY RACK
MODBUS RTU
MODBUS
SCADA CLIENT RTU TO ETHERNET ELECTRICAL CONTROL LINES
GATEWAY
NVR
ACCESS CONTROL
SERVER
LAN ACS 1 to 10
CCTV
SERVER Sensors/actuators
SCADA
ACS
CONTROLLER
... ACS
CONTROLLER
SERVER
MODBUS RTU
AUTOMATION
HVAC PRODUCTION SERVER WITH I/O
CONTROL BOARD MODULES
DAMPER1 DAMPER2 DAMPER3
CONTROLLER CONTROLLER CONTROLLER
FREEZER
MODBUS
GATEWAY
ACS 11 to 19
ACS
CONTROLLER
... ACS
CONTROLLER
PRODUCTION
UNIT GATEWAY
MODBUS RTU
PRODUCTION
CLEAN ROOM DATA ROOM
ROOM
CONTROLLER CONTROLLER
CONTROLLER
Figure 35. CONTROL SYSTEM – Architecture.
8.16. Public Address System (PAS)

A complete public address system shall be provided in common areas for clear
announcements during public addressing, paging, prayer calls and one way
communication during emergency, and/or background music where required.
The system shall be manual and automatic public broadcast. The public address system
will have different types of inputs with different type of priority and shall be interfaced
with fire alarm system to play pre-recorded fire alarm emergency message in case of
fire.
The system shall have the following architecture and contain following components:
• Network Controller.

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• Power amplifiers.
• Call stations.
• Speakers, which will be ceiling mounted in office areas and wall mounted in wide
areas or corridors. Speakers will be for indoor or outdoor.
• CD Player/Recorder.
• Rack cabinets to install the amplifiers.
The PA system will divide the hangar in several zones and different power amplifier types
are used to meet the specific power requirements of each zone. The proposed zones are:
• Zone 1 – Offices.
• Zone 2 – Clean Area
• Zone 3 – Production Area.
• Zone 4 – Offices between Clean and Production Areas.
• Zone 5 – Warehouse office next to Clean Area.
Figure 36. PAS – Zones.

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Figure 37. PAS architecture.
Amplifiers will have 2 outputs and 250W power each output suitable for powering all
speakers connected to them.
The public address rack shall be located inside in the Centralized Data Processing Room,
in the second floor of the offices. The rack will contain network controller, power
amplifiers, power units, etc. Rack cabinet should be powered from external
uninterruptable power supply.
The PA system shall use 70 volts distribution system. Speaker lines shall be supervised.
Cabling for speakers lines shall have a section of 2x2,5mm2. Cables will be routed from
the PAS rack to the speakers using the main communication trays.

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Manufacturing Plants for Composite

Detailed Design. Basis of Design. Large Plant

Detailed Design. Basis of Design. Large Plant

7.4. Carpentry, Glasswork and Metal Works ..................................................... 24

ANNEX 1. GEOTECHNICAL REPORT.

Detailed Design. Basis of Design. Large Plant

ANNEX 2. TOPOGRAPHICAL SURVEY.

ANNEX 3. FOUNDATIONS AND STRUCTURES.

ANNEX 4. PLUBING MATH.

ANNEX 5. HYDROLOGY AND STORM DRAINAGE MATH.

ANNEX 6. IRRIGATION MATH.

ANNEX 7. SEWAGE MATH.

ANNEX 8. COMPRESSED AIR MATH.

ANNEX 9. VACUUM MATH.

ANNEX 10. HVAC MATH.

ANNEX 11. ELECTRICAL MATH.

ANNEX 12. FIRE PROTECTION.

ANNEX 13. TELECOMMUNICATIONS SYSTEMS.

Detailed Design. Basis of Design. Large Plant

1. INTRODUCTION. PROJECT BACKGROUND AND SCOPE

1.1.1. WP1. Proposal for the Aeronautical Components Manufacturing

These components will be manufactured in a production plant, according to their sizes:

• Large Plant: dedicated to the manufacture of components up to 35x7 m.

The work included:

1.1.2. WP2. Implementation of the Layout for the Large Plant

• Layout of the area dedicated to the production of small components.

• Layout of the area dedicated to the production of large components.

1.1.3. WP3. Sizing of the Plant, Offices and other Services

• Operation and production requirements:

o Estimate of the number of workers who will work in the plant.

o Number of workers needed to perform tests.

Detailed Design. Basis of Design. Large Plant

o Number of design engineers.

o Number of process engineers.

o Other necessary workers (quality, logistics, etc.)

o Dimensions for the number of parking spaces.

o Dimensions for offices.

o Dimensions for quality department offices and laboratory.

o Design of meeting romos.

o Design of rest areas, common areas, etc.

o Design of changing rooms and rest rooms.

o Dimensions for ancillary services (transformation centre, compressed air,

o Definition of working conditions (T and H) in each area defined in the layout.

o Specific air treatment needs, such as filtering, considering the conditions of

o Design of the areas with loads exceeding 20 kN/m2.

o Identification of sources of vibration, restrictions and insulation requirements.

o Layout design with overall dimensions and necessary clearance.

o Openings for sunlight.

• Requirements for installations:

o General electrical supply requirements. Power installed.

o Electrical power study for the factories.

o Wastewater removal network.

o Specific power supplies.

o Definition of the production process waste materials.

o Layout of accesses and evacuation routes.

Detailed Design. Basis of Design. Large Plant

This work listed above results in:

1.2. Scope of the Concept Design (WP4)

HEALTH AND SAFETY 1 (*)

Detailed Design. Basis of Design. Large Plant

QUALITY ENG. (PROCESS) 2

MAINTENANCE STAFF 2 (*)

CLEANING STAFF (*)

(*) Could be outsourced