Less than two years after selecting STV to oversee the transformation of a turn of the century former steel foundry into a modernized facility, Boeing recently celebrated the accomplishment with a ribbon cutting ceremony. Joined by members of the U.S Marine Corps, U.S. Navy and U.S. Air Force, Boeing opened the new 350,000 square-foot facility where it will continue to build fuselages for new V-22 Osprey’s and modernize the Marines’ existing MV-22 fleet as part of its Common Configuration – Readiness and Modernization (CC-RAM) program.

STV, a leading program/construction management and design firm, served as owner’s representative for this complex, multi-purpose project and was able to meet Boeing’s ambitious timeframe to begin operations at the new Ridley Township plant with a flexible phased building utilization schedule.

Using proven integrated focused factory initiatives, the new plant provides an advanced working environment for production workers with the addition of new clerestory windows which provide natural lighting throughout as well as multiple conditioned air systems to maintain comfortable temperatures year-round. In addition, there is new office support areas above the production area, a dedicated cafeteria, and numerous energy-saving and sustainability features to meet Boeing’s green initiatives.

As part of this program, a number of innovative solutions were developed to resolve engineering challenges. For the installation of new support steel for the second-floor office area, the project team refurbished and restored a historic Niles DC electric bridge crane. This crane, which is capable of lifting 25 tons, had been a part of the old General Steel & Casting factory’s past, with components dating back more than a century. STV’s on-site team and the manufacturer’s archived records played a key part in getting the crane back into service.

The project team also used Aero Aggregates, a newly developed lightweight fill material made from recycled glass to resolve flooding within abandoned underground utility tunnels that were located below the factory’s new super-flat floor foundations. The new environmentally friendly material was locally sourced from a defunct locomotive factory that was revived around the same time as the Boeing facility.

For more information, contact:

Jill Bonamusa
(212) 614-3354

Jonathan Lucas
(212) 614-3391