Boeing 787 Assembly Plant

Boeing selected North Charleston as the site of a new $750 million assembly plant for the 787 Dreamliner. The 1,037-foot-long assembly plant features 692,000 square feet of covered space and 1.2 million square feet of usable space.

Baker’s $25 million scope of work included multiple contracts covering elevated slabs, foundations, slab on grade, utility tunnels, an electrical vault, and process rail grout. The scope also included a five-story mezzanine, interior and exterior tunnels, trenches, and pits.

The slabs required specific flatness and levelness (FF 55, FL 50). Baker used a 650 Flex mix with nearly 700 pounds of cement per yard to meet these requirements. Baker achieved an actual overall floor flatness of FF 100, FL 60.

The slabs required very specific finish quality tolerances, which Baker achieved with a hybrid concrete mix design that contained nearly 700 pounds of cement per cubic yard. Baker surpassed the slab quality requirements by installing floors with an overall average flatness and levelness of FF 100/ FL 60.

To meet the aggressive project schedule, Baker worked three 10-hour shifts, seven days a week. Safety, quality assurance, and management personnel were represented on all shifts. Baker contributed approximately 300,000 man-hours on-site with no lost time due to accidents.