Raytheon All Up Missile Facility

The Challenge

Raytheon planned to build a cutting-edge missile production facility for the SM-3 andSM-6 missiles on the grounds of Redstone Arsenal in Huntsville, Alabama. At the facility, Raytheon would produce both missile variants in an “all-up-round” package. The facility would be designed for end-to-end production—building, loading ordnance and propellant, testing, and packaging missiles in a ready-to-deploy state.

To accomplish this, Raytheon selected Barge Design Solutions (Barge) for the design of the 20,000-square-footproduction area, which includes production and administrative spaces, as well as site preparation. The project required precision design, state-of-the-art safety, and containment features to accommodate the sensitive materials and processes involved in missile production. The design was also needed to meet strict anti-terrorism and force protection standards. 

The Solution

The 20,000-square-foot production area was designed as a clean room environment with robust mechanical and containment elements. A special conductive force concrete slab floor was designed, and an underslab ventilation system and vapor barrier were installed due to contaminated soil on the site. A special lightning protection system was designed to provide complete shielding of the facility and its highly explosive content.

Barge designed the facility as a secure facility with a loading dock which allowed components being delivered to the site and leaving the site to be loaded in a depressed dock area that was serviced by an overhead crane. The crane was designed to clear span the loading dock area and the adjacent elevated staging area. In addition, Barge completed site preparation and surveying, collaborating closely with Redstone Arsenal engineers to remediate contaminated site soils, worked within very tight constraints of a flood plain, and designed an earthen berm surrounding the test cells. The entire facility meets anti-terrorism/force protection standards.

The Result

Raytheon’s new missile production facility was completed on a fast-track schedule, meeting budget constraints and rigorous safety and functionality standards. Barge played a pivotal role alongside the owner and contractor in a comprehensive cost-cutting initiative, exploring over 50 cost reduction strategies that culminated in an estimated total project savings of around $3 million. The facility positions Raytheon for efficient, safe missile production, fully aligned with anti-terrorism and force protection standards.