Rolls-Royce Advanced Blade Casting Facility

Precision and innovation: building for the manufacturing revival

Rolls-Royce is an iconic power systems company that’s been providing power for aircraft, ships and land applications for over a hundred years.

Its vision is to provide "better power for a changing world".

Nowadays, the company is best known for its aero engines; precision machines that have to be faultlessly reliable.

A key component of every jet engine is the high-pressure turbine blades. Revolving at incredible speeds, in the very heart of the engine, these have to withstand the most extreme temperatures and forces, so they’re crucial to the company’s success.

Project details

  • Customer: Rolls-Royce plc
  • Main Contractor: BAM Construction
  • Architect: Bond Bryan
  • Project Manager: Turner & Townsend
  • Quantity Surveyor: Turner & Townsend
  • Structural Engineer: Buro Happold
  • Services Engineer: Silcock Leedham Consulting Engineers Ltd
  • Value: £24.6 million

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+/-0.2mm Fact icon tolerances govern the casting of these advanced alloy blades
BREEAM Fact icon very good rating being targeted for the building
180 Fact icon people will be working at the plant, many of them local
200,000 Fact icon blades a year could be produced once the facility is fully operational

Cutting-edge engineering

Creating such high-tech elements demands equally high-tech manufacturing facilities. In 2012, BAM started work on the company’s new Advanced Blade Manufacturing Facility in Rotherham.   

The region is rich in skills and expertise, both in precision manufacturing and materials research. At the heart of Yorkshire’s Advanced Manufacturing Park, the Rolls-Royce factory is one of several in the pipeline.

BAM had to deliver a flagship building that reflects Britain’s world-class capabilities in the aerospace sector.

As befits this technology-led project, BAM has used state-of-the-art 3D modelling software to design, plan and manage the development.

BAM Regional Director James Wimpenny explains why this is so crucial: “The Building Information Modelling technology is exciting, as it allows our engineers to predict challenges and build in solutions.”

Leading an industrial renaissance

The new Blade Casting Facility will create valuable local jobs, most of them requiring high levels of skill.

At the ground-breaking ceremony, Business Secretary Vince Cable talked about how the Rolls-Royce initiative was a great example of the renaissance in British manufacturing.

For BAM, it’s just one of a growing number of projects in the high-tech sector, where meticulous quality, great design and sustainability are top of the agenda.