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B737 2nd Life aeroSTUDIO BALL STATE UNIVERSITY, DEPARTMENT OF ARCHITECTURE 2014
COPYRIGHT Š 2014 Department of Architecture Ball State University ALL RIGHTS RESERVED No part of this publication may be reproduced in any manner without permission of Ball State University: Department of Architecture. The information contained is that of individuals and does not represent the views of Ball State University. All images courtesy of Ball State University and Glenn Cramer and Justin Krajci. CONTACT Department of Architecture Ball State University Muncie, IN 47306 glennrcramer@gmail.com jskrajci@gmail.com
TABLE OF CONTENTS 04 About aeroSTUDIO 06 Advisors 08 Project Proposal 10 Methods 12 Abstract 17 Precedence Studies 28 Literature Review 31 Trip to UAM 36 Overview 38 Designing an Organization 50 Designing a Factory 62 Designing a Product 78 Final Presentations 80 Display 84 Credits 02
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ABOUT aeroSTUDIO
GLENN CRAMER BIO: Born and raised in Richmond, Indiana, Glenn attended Ball State University for his undergraduate studies and will soon be receiving his M.Arch Degree in May of 2014. He chose to take the Aero Architecture Studio because he was inspired by the precision and strength that Boeing airplanes bring to the field of architecture. He is continuing to work with aviation material and its use in architecture for his thesis project. Overall Glenn is passionate about designing for people and the environment.
JUSTIN KRAJCI BIO: Justin Krajci was born in Munster, Indiana and spent his youth in Crown Point, Indiana. Justin received his Masters of Architecture degree in 2014 from Ball State University, the same university where he received his B.A. degree. Some of Justin’s hobbies include: rooting for Chicago sports teams, exercising, and video games. In architecture, he finds a lot of inspiration from the firm, Architecture for Humanity. Justin is always looking for chances to give back to his community.
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ADVISORS MAHESH DAAS BIO: Dr. Mahesh Daas is the ACSA Distinguished Professor of Architecture and Chairperson of the department of architecture. He considers himself to be an unteacher and an intellectual venture capitalist who promotes innovation in education, and uses design thinking to solve social and organizational problems. More about Dr. Daas can be found at www.mahesh.org
DR. MICHAEL HOLMES BIO: Dr. Holmes became the Chairperson of the Journalism department at Ball State University in 2013. He has designed and managed nearly 35,000 hours of field-based observational research on consumer exposure to media. This work includes the landmark Video Consumer Mapping Study for the Nielsen-funded Council for Research Excellence. In 2009 he was named a Centennial Scholar of Communication by the Eastern Communication Association.
HARRY EGGINK BIO: Professor Eggink has 35 years of teaching experience in the area of architecture and urban design and has maintained a small professional Architecture/UD firm for about the same duration. Eggink has engaged in more than a hundred Community Based Projects (CBP) and small town charrettes in Indiana as well as the East coast, and has exhibited, published, and lectured extensively on the CBP’s community participatory process, public communications, and visual methodologies.
KERI WRIGHT - Consultant BIO: Keri Wright is the Chairman & CEO of UAM. Keri began her tenure at UAM as Vice President of Asset Management and was promoted to Chief Operating Officer in 2007. As COO, Keri transformed UAM into a multi-million dollar company. Keri was a thought-leader in capital asset management, business development and strategic planning.
GOUTHAM RAMDAS - Consultant BIO: Goutham Ramdas is working at Universal Asset Management as a Purchasing Specialist. Some of his previous accomplishments with the company include management of our multi million dollar aircraft inventory, development of processes to improve and streamline all inventory operations within our global distribution center, management of all surplus inventory that UAM is responsible for.
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PROJECT PROPOSAL
Justin and Glenn hard at work for aeroSTUDIO
aeroSTUDIO is working with an identified problem of how airplanes are used after they reach their end-of-service. In most cases, the commercial airplanes take their last flight out to an airplane graveyard in Arizona, where they will sit to rust and decay. Currently, the airplanes sit in a “graveyard,� while there is still no plan in place to reuse the planes. At aeroSTUDIO, we identify this as a major problem and have come up with a sustainable solution to reuse, repurpose, and re-distribute these old and unused airplanes. Our solution is to reroute the final flight of these airplanes, ideally to our facility in Indianapolis, where the airplanes will be deconstructed and repurposed into a myriad of different products. For example, we can reuse a fuselage and many other parts of the plane to create affordable housing, disaster relief pods, several types of infrastructure, furniture, medical relief facilities and other installations created by in-house designers. At the College of Architecture and Planning at Ball State University, Harry Eggink has run several studios that demonstrate many realistic ways to recycle and repurpose the material. Commonly, students use main sections of the fuselage to create these designs previously stated. At our facilities we take the airplanes and deconstruct them. Post deconstruction, the designers will determine what scenario they will be repurposed for. The pieces will then be distributed to the proper location where the material can be rebuilt on a site. Our goal is to create an organization centered around the process of repurposing used airplane material.
“If you want something new, you have to stop doing something old� -Peter F. Drucker
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METHODS
RESEARCH Throughout the thesis duration, we have done very detailed research and studies into other businesses that we looked to emulate. Studying how the businesses were started, why they are still successful, and the key components to their business model have helped us better organize.
INTERVIEWS Throughout the interview process we will interview employees of Boeing that are in charge of recycling the airplanes, students, who have designed prototypes with the recycled airplane parts, and we will also interview our advisors, Dr. Mahesh Daas, Dr. Michael Holmes, and Harry Eggink.
DIAGRAMS With diagramming, we will work out Project 1 and all of its details. For example the Business Model Canvas helps out better plan our organization. Transportation diagrams will help better visualize the process and the deconstruction diagrams will help to make the project more feasible.
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ABSTRACT
737_2nd_LIFE How can we take unwanted, less valued, spent material from one industry and apply it to another industry? Everyday the aviation industry retires their less efficient airplanes to make way for new state-of-the-art airplanes, sending many of these old airplanes to the desert or scrap yards. As the rate of retirement steadily rises we look for alternative ways to capitalize on the material not being used for it’s high potential. This thesis examines how we can reuse Boeing 737 airplanes in extreme environments. Our exploration has been less about geometry and more about process. We have developed the logistics that connect aircraft material to designers and their locale in an effort to expand the value of this material while enriching the design industry. In short, we hope to increase the distribution of spent aviation material. The outcome of this thesis addresses the current methods of deconstruction and how we can improve upon them, the ideal use for potentially valuable fuselage material and how this may work contextually, while considering the delivery methods necessary to move the material.
THE ISSUE
Airplane Graveyard Looking at the image to the right, you can see the vast amount of airplanes. There are thousands of these planes sitting in deserts in the American Southwest. Many of these planes will sit and not be used. If they are lucky, they will be scrapped and the aluminum will be melted and recycled. Of the companies that recycle these planes, they often find waste with the fuselage. Instead of scrapping the aluminum of the fuselage, aeroSTUDIO will reuse the fuselage, making it into a marketable product.
PRECEDENCE STUDIES Using Alexander Osterwalder’s Business Model Canvas, we have broken down each of the examined businesses into his nine buildings blocks: customer segments, customer relationship, channels, value propositions, key activities, key resources, key partners, cost structure, and revenue streams. Studying the relationships between these buildings blocks can help create a successful business model.
A.M.A.R.G.
AMAZON.COM Customer Segments – Who is value created for? Amazon creates value for a mass market. Essentially anyone within their distribution network and Internet access has most likely been a customer at least one time. Customer Relationship – Type of relationship you are developing with your customers. Since Amazon is an online shopping, it is a self-service business. The automated shopping system allows customers to shop easily and conveniently. You can buy and receive goods without leaving the comfort of your own house. Channels – How do you reach your customers? Amazon’s reaches its customers in a very simple fashion, Amazon.com and applications. Again, using the Internet to touch base with your customers benefits the business of the convenience it offers. Value Propositions – Services that create value. Amazon offers an array of products with varying price points. If you are an Amazon Prime user, you can receive free two day shipping for Prime eligible products. Also, third party organizations use Amazon to sell their products. These users offer both new and used products. Key Activities – What do you really need to perform well at? Amazon needs to succeed at merchandising. As long as they continue to provide good products, prices, selections, and good delivery techniques, they will remain as a top business. Key Resources – Which assets are indispensable? On the physical side, Amazon has a network of warehouses that are necessary to keep them in business. On the human side, they have web and application develops, whom are equally as important to the success of Amazon. Key Partners – How you can help leverage your business models? Mentioned earlier, Amazon has a network of sellers that contribute to the business. Also, suppliers and manufacturers are key partners to the success of Amazon; without these, Amazon does not have a business. Cost Structure – How are costs associated with the business? Amazon is a cost-driven business, which basically means they use manufacturing and production costs as its basis for pricing. Additionally, uses the “economies of scale” ideology. Revenue Streams – How and through which pricing mechanisms your business model is capturing value. Amazon is capturing value from retail sales, the Kindle and its content, commission on
reseller sales and the Amazon Prime monthly subscription. Additional Notes and information: Amazon utilizes over 80 warehouses and centers, which are scattered throughout the world. About the size of a football field, the factories take care of sourcing, organizing, packing and shipping several million orders a day. Within the factory, Amazon sorts objects by size, rather than type in order to maximize the shelf space. In December 2013 Jeff Bezos, founder of Amazon, unveiled a plan to ship packages with drones.
eBAY Customer Segments – Who is value created for? Value is created for a mass market. eBay is basically looked as a convenient online pawn shop, that uses online peer reviews to create a value for products. Customer Relationship – Type of relationship you are developing with your customers. Another self-service business, eBay has an indirect relationship with its customers. Channels – How do you reach your customers? eBay reaches its customers in three main ways: ads, applications, and ebay.com. Value Propositions – Services that create value. eBAY is unique because you can buy and sell products from your house. Additionally, you can typically find a wider range of prices at eBAY, which can usually lead to cheaper products. Key Activities – What do you really need to perform well at? In order to maintain their business, eBAY needs to be ahead in two major activities: technology and marketing. As tablets and “smart” devices become more popular, eBAY needs to continue to be technologically advanced to be competitive. Like most big shopping companies, marketing play a large role the in the success of the business. People need to know who you are. Key Resources – Which assets are indispensable? eBAY remains a successful business because it has almost ANY product you could want, as well as the people who want to purchase those items. Key Partners – How you can help leverage your business models? The partners for eBAY are simple. Buyers and sellers. The buyers and sellers make eBAY what it is today. Cost Structure – How are costs associated with the business? eBAY makes money in two major ways. After someone buys a product, eBAY receives a percentage of the final value. Also, eBAY makes money by allowing advertisements on their page. Revenue Streams – How and through which pricing mechanisms your business model is capturing value. The revenue streams for eBAY come from the following: advertisements, shipping and revenue sharing agreements.
Additional Notes and information: eBAY provides a great value to small businesses and retail shops. A service called GSI helps the small businesses put their inventory online, which allows customers to see their entire range of products.
BOEING Customer Segments - Who is value created for? Boeing supports airlines and U.S. and allied government customers in 150 countries. Approximately 70 percent of Boeing commercial airplane sales (by value) go to customers outside of the United States Customer Relationship – Type of relationship you are developing with your customers. The Boeing sales team and airlines work together as a partnership. Many of the airlines influence the design of the aircraft. The customers and their pilots receive training about owning and operating the aircraft. A relationship driven by price, efficiency and reliable products Channels – How do you reach your customers? Boeing is often working one on one with its customers and does this by locating offices in 70 countries. Value Propositions – Services that create value. One defining value proposition for Boeing has been their ability to refocus on enhancing existing strengths in product R&D and manufacturing while at the same time reducing the costs of these efforts. With the average aircraft development process taking near 25 years to complete, Boeing was in need of improved processes in terms of both cost and speed. In response, the company invested in an interactive CAD system which not only addressed these issues, but provided the company with a number of additional benefits including greater technological flexibility and capability. Key Activities – What do you really need to perform well at? Boeing focuses all efforts on design and production of commercial airplanes, military aircraft, Network & Space Systems, Global Services & Support, and Defense/ Space & Security. Key Resources – Which assets are indispensable? The company employs more than 170,000 people across the United States and in 70 countries, and leverages the talents of hundreds of thousands more skilled people working for Boeing suppliers worldwide. Boeing has factory and office locations in 70 countries Key Partners – How you can help leverage your business models? The Boeing supplier network includes approximately 28,000 suppliers and partners Cost Structure – How are costs associated with the business? Boeing puts innovation and efficiency in order to stay ahead of its competition. Revenue Streams – How and through which pricing mechanisms your business model is capturing value.
Primary revenue streams for Boeing are from Commercial Airplanes, Boeing Military Aircraft, Network & Space Systems, Global Services & Support, and Defense/ Space & Security. Combined revenues totaled $81 billion in 2012. Additionally: - Boeing is organized into two business units: Boeing Commercial Airplanes and Boeing Defense, Space & Security, and is supported by Boeing International.
AMARG America’s Military Aircraft Boneyard is what used as a precedence pertaining to process. The process at the boneyard will help us determine how an aircraft is recycled and repurposed. Aircraft Storage and Disposal Before each aircraft arrives, a controlling agency will determine what level of preservation is required for the aircraft. They will also take a closer look and determine if there are any parts or subassemblies that should be removed. These parts will often be sent to a depot-level overhaul program to keep other aircraft flying in the fleet. According to AMARG, preservation is broken down into 5 levels of preservation: • Type 1000 - Long-term storage, where the aircraft will be maintained with the potential of being put back out into the fleet. • Type 1500 - Long-term storage, where the plane is not expected to be back into the fleet, but some of the subassemblies and internal parts may be used in the future. • Type 2000 - This signifies an aircraft will be in programmed parts reclamation storage, where the aircraft is expected to yield as many parts as possible to keep other airplanes in flying shape. Removed parts will be cleaned, tested, packaged, and shipped to repair depots around the world. • Type 3000 - Denotes an aircraft in flyable hold storage, often applied to airplanes awaiting a transfer to a foreign government. • Type 4000 - Signifies an aircraft that has had every usable part reclaimed and is ready to be recycled. The process of the aircraft that arrives at the boneyard is as follows: 1. The aircraft lands 2. The crew deplanes 3. An inventory number is added a. PCN or Production Control Number, an 8 letter/digit code is applied in spray paint 4. Any armament and ejection seat is removed a. After this step, the airplane is awarded a green spray painted nose to serve as an identifier that the previous step has been completed 5. A detailed inventory of the aircraft and the contents is made a. Classified items are secured b. Completion of this task earns a gold spray-painted number 7 near the green
spray paint 6. The fuel system is drained and the engine is preserved 7. The hydraulic system is thoroughly washed and sprayed with a corrosion inhibitor 8. The craft is then towed to a sheltered area to begin the sealing process 9. The upper sides of the aircraft are taped, leaving the lower portion open for air circulation 10. Engine inlets and exhausts are covered then the first two coats of plastic “spraylat” are applied a. The first layer is black and the top layer is white to reflect sunlight. The combination of open lower areas with spraylat applied to canopies and upper surfaces allows an aircraft’s interior to maintain a temperature within 15 to 20 degrees of the outside air temperature. b. Every six months after arrival, aircraft are inspected to ensure that the elements have not damaged the spraylat. c. After four years the planes are recycled through the preservation process. 11. Aircraft will depart in one of two ways: under their own power, or on a truck a. 25% of all aircraft have flown out for further service 12. AMARG technicians prepare the aircraft for flight by withdrawing the plane from storage, inspecting and repairing or overhauling systems, and modifying an aircraft to meet the standards set by Time Compliance Technical Orders a. Many aircraft or subassemblies such as a fuselage will be trucked from the center
UAM
Business Study Universal Asset Management (UAM) is a company located in Memphis, Tennessee. We used UAM as a precedence because they are doing work similar to what we would like to achieve. At UAM they buy, sell, lease, and manage a wide variety of commercial aviation assets for an array of clients. Currently, UAM will take the old airplanes, recycle the avionics, and reuse whatever possible in new airplanes. UAM is unique, wherein it takes other scraps of the airplane to make furniture. UAM specializes in the recycling of commercial airplanes of many types (from Boeing to Airbus).
LITERATURE REVIEW Introduction Currently, we are investigating the process of creating a delivery system for Boeing commercial airliners as they begin their “second life.� This delivery system will be important to architects and designers who utilize aircraft material in their work. We believe this to be advantageous to the work we do and to the Boeing Company, which is currently, seeking high value solutions for decommissioned/ end-of-life airliners. An analysis of the airliner deconstruction process reveals one problem with the distribution of spent material: continue to under-utilize major percentages of decommissioned airliner material or find high-grade construction uses for end-oflife airliners. In recent years, 85% of these materials have been used in low-grade industrial processes and sent to landfills. Theme: Underutilization - Dismantle, destroy and dump A look at the current and potential future of airliner waste streams. Many operations are looking for high-grade industrial solutions. The following is an overview of characteristics of the theme (commonalities, differences, nuances) Literature: Carberry, William. (2008, April). i. airplane recycling efforts- benefit Boeing operations Aero Quarterly , Retrieved from http://www.phantomworks.org/commercial/aeromagazine/articles/qtr_4_08/pdfs/ AERO_Q408_article02.pd (What are current operations and how they may improve over time? At this point in time, major airlines and airplane manufacturers cooperate through AFRA (Aircraft Fleet Recycling Association) to maximize efficiency and profits when responsibly disposing of their aircrafts. Boeing has recently called upon AFRA to responsibly plan for second life. Primarily the importance of recycling composite materials being used on the newest Boeing airplanes. ) N.A. (2011). Where planes go to die. BBC World News, Retrieved from http://www.bbc. co.uk/programmes/p00fvjq3 (A look at one scrap operation in the UK. We may refer to this type of operation when attempting to understand the disassembly processes for large aircrafts. This is also a good example of an operation that retains material over many years, making our ideas for high grade recycling and reuse applicable around the world. ) Reals, K. (2011). Aviation industry under pressure to reduce landfill waste from scrapped airliners. FLIGHT International, Retrieved from http://www.flightglobal. com/news/articles/aviation-industry-under-pressure-to-reduce-landfill-waste-fromscrapped-351597/ (Near future goals for the scrapping industry. The industry is changing, we have an
opportunity to capitalize with our ideas. “Dismantling and recycling scrapped airliners is becoming big business. Estimates from the Aircraft Fleet Recycling Association (AFRA) put the number of aircraft destined for the junk yard over the next 20 years at 12,000, and pressure is growing to reduce significantly the amount of waste that goes to landfill.”-Reals) Airliner graveyard – The current state of aviation “second life” Veronico, N. (2010). Americas military boneyard. AMARG, Retrieved from http:// books.google.com/books?hl=en&lr=&id=z8IRbI3kIlsC&oi=fnd&pg=PP1&dq=arizona airplane graveyard&ots=ZtRQ3--UG9&sig=2x2-9jiHZ_BqV2fAA0CQZnew_SI (How are other entities dealing with their used aircrafts? For the military, parking them in the desert has been the primary course of action.) N.A. (Producer). (2012, March ). Boneyard Project – Airplane Graffiti [Web Video]. Retrieved from http://www.urbanartcore.eu/boneyard-project-airplane-graffiti-video/ (This is how graffiti artists use decommissioned airplanes.) Sydney Morning Herald. (2011, May). Australia gets first plane ‘boneyard’ outside us. Retrieved from http://www.smh.com.au/travel/travel-news/australia-gets-first-planeboneyard-outside-us-20110527-1f77f.html (“Alice Springs has been selected to be the first aircraft “boneyard” outside the United States. Similar to the massive Pinal Airpark in Arizona, it will take planes being decommissioned from service, which will be stripped of parts like engines, electronics and wiring to be re-cycled. Airlines will also be able to store aircraft as big as the A380 when they are not being used.”-SMH) Theme: High-grade / high-value solutions – The importance of finding high-grade industrial recycling These studies overview the industry goals for high efficiency reuse and the goals of designers and architects who create with aviation material. Literature: Perry, J. (2012). Sky-high potential for aircraft recycling. Rubriek, Retrieved from http:// www.afraassociation.org/NewsDocs/12_Mar_RecyclingIntl.pdf (An overview of some of the best methods for industrial use. “As increasing numbers of aircraft are retired from service, the author of this article speaks to original equipment manufacturers (OEMs), dismantlers, parts re-distributors, materials recyclers, researches and the Aircraft Fleet Recycling Association to discover how air-craft can
be born again.”-Perry) Construction – architectural uses for aviation material Kim, V. (2013, September). Most creative ways to recycle a plane. Retrieved from http://www.cnn.com/2013/09/04/travel/recycled-planes/index.html?iid=articl (Low quality and uneconomical ways to reuse old aircraft) Wang, S. (2013, December 13). Old planes, New Use. Indianapolis Star. Retrieved from http://www.indystar.com/story/news/education/2013/12/12/ball-state-architectsdream-up-new-uses-for-old-planes/4005941/ (Covered in both the Muncie Star Press and The Indianapolis Star before moving on to The AP, this article covers one studio’s journey when they explore the creative solutions for creating architecture with used aircraft material.) “Aero architecture” created by Prof. Harry Eggink’s Studio (Creative ways to utilize aviation material to create habitat, commercial space, disaster relief, and installations) Conclusion: An evaluation/critique of the existing literature. This literature demonstrates the current state of airliner recycling and second life. Most of the information available is geared toward the dismantling and destruction of spent aircraft. Few studies discuss the use of this material in high-grade and highvalue situations. All of this information is important when examining new ways to dismantle and distribute materials for construction and architectural fields. The next steps for research will be to ask how we as a thesis team can best partner with the key players in the aircraft reuse environment. A few of those partners are: Boeing, Harry Eggink, Bill Carberry, The Aircraft Fleet Recycling Association, and boneyard owners.
TRIP TO UAM While conducting research at aeroSTUDIO, we decided that we needed to see the recycling of airplanes in person. We started our search by creating a map and identifying each member of AFRA (Aircraft Fleet Recycling Association) and seeing which company was located closest to us. This would allow us to take one day of travel to see the company. After calling several places, we eventually got a hold of Keri Wright, CEO at UAM. She invited us to her facilities in Memphis, Tennessee and Tupelo, Mississippi. After seeing the recycling and repurposing of airplanes in person, we then gained a better appreciation and understanding of the overall process.
OVERVIEW
For the final project proposal, aeroSTUDIO decided to break the project up into three different parts. The three parts include: designing an organization, designing a factory, and designing a product. In order to design an organization, we needed to figure out how to organize. This process led to creating a business model, a material distribution plan, analysis of current operations vs. our operations, and a deconstruction plan. When designing a factory, we needed to determine a site, and understand the program for the factory. Lastly, when we designed a product, we wanted to create a something that could appeal to a specific market.
project 1: DESIGNING AN ORGANIZATION
project 2: DESIGNING A FACTORY
project 2: DESIGNING A PRODUCT
DESIGNING AN ORGANIZATION
Business Model
Key Partners: Airplane recyclers Universal Asset Management Shipping Companies Aircraft Fleet Recycling Association
Key Activities: Inventory Design/ Prototype Production Delivery Logistics
Key Recourses: Tax Incentives Facilities Plant, Factory, Office, Storage Retired Airplanes People/ Knowledge Engineers, Architects, Designers, Vendors/ Contractors
Value Propositions: Mobile Unit Proprietary Designs
Cost Structures: Airplane Fuselage People/ Employees Facilities Fabrication Equipment Builings
Customer Segments: Disaster Relief Agencies Researchers Explorers
Customer Relationships: Meet Collaborate Work case by case
Channels: Freight Rail Ship Boeing Dreamlifter Parcel Services
Revenue Streams: Mobile Unit Sales Proprietary Designs
DESIGNING AN ORGANIZATION
Material Distribution
DESIGNING AN ORGANIZATION
Current Operations vs aeroSTUDIO’s Plan
Below is a diagram that explains how planes are currently being recycled and reused. The dotted blue line outlines aeroSTUDIO’s plan to step in and alter the recycling process.
1.
INITIAL CONSTRUCTION
LIFECYCLE
AIRPLANE GRAVEYARD
2.
DECONSTRUCTION
LIFECYCLE
RECYCLE/REPURPOSE
aeroSTUDIO Plan
DECONSTRUCT
REPURPOSE
INHABIT
Deconstruction Plan After studying several businesses and organizations, we designed the most efficient and effective way to deconstruct the airplane. Below is a 12 step diagram that simplifies the process.
1 Plane lands at the airstrip.
2 Crew deplanes.
3 Plane is towed to a factory to prepare for deconstruction.
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The aircraft is thoroughly examined and added to the companies inventory.
5 Plane is throroughly cleaned.
6 The fuel system is drained.
7 The engine is taken out and is preserved.
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The deconstruction process begins. The plane is now being separated into several pieces.
9 Each part of the plane is sorted and added to the inventory.
10 After the sorting process, the parts are taken to the appropriate on-site factory.
11 The reconstruction process begins.
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After the reconstruction process, the new construction will be shipped away by the most appropriate means of transportation.
SITE
Indianapolis, IN - Old Indianapolis Terminal aeroSTUDIO decided to use Indianapolis, Indiana as the site for their facility. The Indianapolis International Airport has been moved leaving the old facilities vacant for our use. We can use the existing airstrip to bring planes in and route them to our facility where we will recycle and repurpose them.
BOEING 737 The Boeing 737 is a critical component in the aeroSTUDIO operation. The fuselage dimensions are the most important of all its specifications. As a short- to mediumrange twin jet narrow-body airliner, it has served as a workhorse for many airlines, making it an abundant resource for us as they look to upgrade to new more efficient 737’s in the years to come.
The fuselage diameter measures 12’-3”, allowing it to be transported via rail and or freight. In total, 7,980 units of the Boeing 737 have been built and delivered as of March 31, 2014. With another 3,794 still to be delivered and orders of another 1,807 for 2017, there will be a good supply of 2nd life material for the growing reuse industry.
12’ Fuselage 117’ Total
Data from Boeing.com through end of March 2014
DESIGNING A FACTORY
In essence the factory is designed to operate in the opposite fashion of the Boeing factory. When a retired plane lands it will proceed through a deconstruction process that exists within the facility. The final product is the outcome of the factory. The architecture of the factory includes a full length lightshelf and solar panel.
6. shipping
storage
5. wing removal/fuselage disassembly
gcjkSTUDIO
design management
storage
tooling
4. landing gear/exterior parts removal
2. engine removal
1. fuel/hydraulic removal
disassembly management
3. interior/avionics removal
DECONSTRUCTION PROCESS
High-value material redistributed
Decommissioned aircraft
Disassembly process
Clean and repurpose for customer use
Cut to fit Pod specifications 12’ wide x 40’ long
Freight/Rail Transportation Fits on a flatbed
TRANSPORTATION
The B737 and how it relates to rail/ freight transportation One primary goal of the project was to solve transportation issues. Many architectural concepts of aircraft reuse are faced with crippling material distribution issues. Highway restrictions limit the length, width and height of cargo. The B737 fuselage is a perfect fit for transportation.
Rapid deployment via helicopter If need be, the Pod can be airlifted into a disaster or war zone to provide support operations. A helicopter may also be essential when deploying in an environment with limited infrastructure.
Fuselage Pod
DESIGNING A PRODUCT
The Fuselage Pod is a self supporting unit designed to be placed in extreme environments. Researchers and first responders alike will be setting up work out of these shelters. If disaster strikes, search and rescue operations will be conducted from this supportive unit. As well as Arctic or desert researchers looking to understand life in extreme environments will find the aeroSTUDIO Pod indispensable.
Early Studies
see part below
fuselage part
One key feature of the pod is its ability to connect and expand. The pod can deployed as a stand alone unit, deployed as a pair, or connected into a community configuration (above). The connection module (left) shows how it can serve as a central hub, primarily supporting communications.
The pod created from the B737 fuselage is rapidly deployed and highly mobile. These characteristics would not be possible without using a B737. The section shows the overall flexibility of the asset inside and out. Possible deployment situations include disaster relief, research, search and rescue, and nomadic communities. Unpredictable environments require the pod to be elevated. Floods, snowdrifts, and predators are all threats. Self-sufficiency is a key goal when placed in a compromising environment. The pod is equipped with systems to achieve this goal as demonstrated. With this pod, we are taking advantage of and preserving the engineering that went into its design as an aircraft. The light weight property of the aluminum and rigidness of its structural design contribute to the 2nd life.
FINAL PRESENTATIONS
UNCC - Charlotte, NC
As guests, we presented our work to a panel of critics at UNCC’s annual CriticalMASS conference. This opportunity allowed us to share our ideas with professionals and students from twelve other highly regarded architecture schools from across the southeast. In total, a group of over 40 students and faculty were in attendance for our review.
Ball State University - Muncie, IN Our final review was held on April 28th and proved to be extremely helpful in terms of feedback from the reviewers. Many supportive comments were made and a good question was brought to our attention, “How can the pod be priced in such a way that would allow customers to make their own upgrades and customizations to best fit their needs?�
DISPLAY Boards featuring business model diagrams
CNC milled frame
Looping video display featuring aircraft graveyards and scraping operations
Interior of fuselage skin
Exterior of fuselage skin
COMPOSITION
PROJECT TWO: FACTORY
SOUTH ELEVATION
T w c v s t o a a
FACTORY INTERIOR
FACTORY INTERIOR
ABSTRACT: How can we take unwanted, less valued, spent material from one industry and apply it to another? Everyday the aviation industry retires their less efficient airplanes to make way for new state-of-the-art airplanes, sending many of these old airplanes to the desert or scrap yards. As the rate of retirement steadily rises we look for alternative ways to capitalize on the material not being used for it’s high potential. This thesis examines how we can reuse Boeing 737 airplanes in extreme environments.
25% WASTE
Our exploration has been less about geometry and more about process. We have developed the logistics that connect aircraft material to designers and their locale in an effort to expand the value of this material while enriching the design industry. In short, we hope to increase the distribution of spent aviation material. The outcome of this thesis addresses the current methods of deconstruction and how we can improve upon them, the ideal use for potentially valuable fuselage material and how this may work contextually, while considering the delivery methods necessary to move the material.
75% RECYCLE RATE High-value material redistributed.
Decommissioned aircraft
AIRPLANE GRAVEYARD - ARIZONA
INDIANAPOLIS, IN
Disassembly process
There is a 75% recycle rate, with the fuselage accounting for the majority of the 25% waste.
Repurpose for customer use.
Size = 12’ Wide x 40’ Long.
Freight/Rail Transportation. Fits on a flatbed.
Transportation is one of the biggest issues and concerns that have acted as a guiding principle in the project. When working with the aircraft, it is important to determine what model can fit on the highway. Because our business is centered on the quick deployment of these “fuselage pods,” we have made a conscious effort to design a quick and very mobile structure. The Boeing 737 is the most ideal aircraft for aeroSTUDIO. One, the size of the 737 is ideal for shipping. With a diameter of 12ft, the fuselage pod can easily fit on a tractor trailer flatbed. Second, Boeing continues to build the 737 model at a high rate, which also means that the 737 model will be retired at a high rate. The process of transportation is shown in the images atop the board. After the plane lands it will be sent through the deconstruction and repurposing processes at the Indianapolis factory. Upon its exit, the fuselage will be shipped via freight, rail, or airlifted to its final destination.
SHIPPING VIA RAIL
PROJECT THREE: FUSELAGE POD
SHIPPING VIA CHINOOK
ARCTIC LAB
(SEE PART BELOW) LINEAR CONNECTION
h The pod created from the B737 fuselage is rapidly deployed and highly mobile. These characteristics would not be possible without using a B737. The section shows the overall flexibility of the asset inside and out. Possible deployment situations include disaster relief, research, search and rescue, and nomadic communities. Unpredictable environments require the pod to be elevated. Floods, snowdrifts, and predators are all threats. Self-sufficiency is a key goal when placed in a compromising environment. The pod is equipped with systems to achieve this goal as demonstrated.
CONNECTING THREE TOGETHER
EXPLODED AXON
ARCTIC LAB
CONNECTION
DISASTER RELIEF
SECTION PERSPECTIVE
DISASTER RELIEF
CREDITS Special thanks to Dr. Mahesh Daas and Dr. Michael Holmes
Special thanks to thenounproject.com: Matthew Exton, Dmitriy Lagunov, Paul te Kortschot, Dylan Voisard, Paul Tynes, Ilsur Aptukov, Gilad Fried, Antonio Petraglia, Modik, Mitchell Harris, Kenton Quatman, Oliviero Fiori, Simon Child, Proletkult Graphik, Harm, Adam Zubin, Naomi Atkinson, and Jens Tarning.