High-tech Hexcel-lence

Hexcel Corporation's new home in West Valley City is the largest high-performance carbon fiber manufacturing facility in the world.
By B. H Wright

The days of the commercial industrial market consisting primarily of boring, staid (read: ugly) warehouse and manufacturing buildings are long gone, as employee-conscious corporations and forward-thinking real estate developers have been realizing the value of housing employees in spaces that sizzle with stylish interior designs with loads of on-site amenities.

Hexcel Corporation did just that with the design of its most significant recent project in West Valley City, a $34 million, 105,000-SF facility dubbed the Center of Research & Technology Excellence, which includes the largest high-performance carbon fiber manufacturing plant in the world, along with housing Hexcel's aerospace matrix operations.

The center is "designed to encourage and inspire our team to dream big and ensure that our customers are awarded the strongest, lightest weight, most durable advanced composites that the world has ever seen," said Nick Stanage, Hexcel Chairman, CEO and President.

He said that when the Center opens, “you will be surrounded by everything it means to be a leader in advanced composites technology. You will see high-tech labs and cutting-edge research and testing equipment. Our lobby will showcase advancements and innovations that are propelling the future in commercial aerospace, space and defense, and industrial markets.”

Sharp aesthetics and providing optimum working conditions are a must for employers in a market with a current state unemployment average hovering just over 2% and in a society where the workforce is increasingly opting to work remote (at home) either full-time, or with a hybrid/flex schedule.

The primary objective of the facility is to serve as a catalyst for research and development in advanced composite technology, with a specific focus on aerospace, space, defense, and industrial applications.

According to Mike Phillips, VP of Project Development at R&O Construction's Salt Lake office, the fast-track design-build seamlessly blended a tilt-up laboratory with a two-story Class A office building, illustrating the owner's attention to high quality and optimum design.

"The entire team was focused on schedule and cost throughout the process, while meeting owner's requirements and needs. It was a very successful project."

The facility's design transcends conventional manufacturing and research spaces. Instead of a stark separation between these functions, the building integrates both—fostering an environment where scientists and production personnel can collaborate seamlessly. This approach underscores Hexcel's commitment to innovation and how diverse functions can coexist within the same space.

One of the project's most noteworthy contributions lies in its commitment to sustainability. Hexcel actively recycles carbon fiber prepreg composite cutoffs to produce composite panels that find applications in commercial markets. By upcycling and repurposing materials, the project demonstrates a forward-thinking approach to resource utilization and waste reduction.

In a resourceful move, the tilt panels were utilized as the crane path to avoid potential soil issues. This approach was executed after thorough consultation with engineers, resulting in a seamless process with all panels standing within a short timeframe, without any compromise to structural integrity or aesthetic appeal.

Exterior Trespa panels were strategically oriented to create a dynamic carbon checkerboard pattern, aligning with the aesthetic of Hexcel's innovative products. This deliberate choice not only showcases a visually striking design element but also reflects the company's commitment to excellence in composite materials.

Tilt-up panels underwent a meticulous sandblasting process to enhance their carbon-like appearance. This technique, applied after curing and installation, contributes to the overall visual effect and reinforces the project's dedication to craftsmanship.

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Hexcel’s bold investment in the Beehive State is evident by its world-class manufacturing and office facility, which includes spacious, well-lit, colorful interiors (following page) that appeals to today’s working class. (photos courtesy R&O Construction)

This project integrates functional efficiency and aesthetic excellence. The design process centers on Hexcel’s creation of high- performance composite materials. Involving a meticulous examination of the unique materials produced by Hexcel; carbon fiber, honeycomb, and other fiber-reinforced matrix materials.

Carbon fiber served as a key focal point due to its distinctive visual characteristics. Beyond its black hue, the material revealed intricate textural qualities that allowed it to refract and reflect light in multifaceted ways. This observation expanded the design palette to encompass various neutral tones, each offering a distinct visual impact. Moreover, the 45-degree diagonal weaving pattern inherent in carbon fiber served as a profound source of inspiration, influencing various exterior material expressions.

Hexcel's honeycomb material, characterized by its warm tones and light-filtering properties, played a pivotal role in infusing elements of warmth and luminosity into the project. This was achieved through the strategic application of wood-toned cladding and expanded metal panel window coverings. The honeycomb's translucency allowed for the gentle filtration of natural light, enhancing the overall spatial experience.

The color palette adopted for the project predominantly revolves around neutral shades, including blacks, grays, whites, and natural wood tones. However, strategic injections of Hexcel's signature blue were strategically employed to infuse personality and vibrancy into the space. Additionally, the project's exterior glazing was carefully selected to be dark yet semi-reflective, capturing reflective glimpses of the surrounding natural landscape.

Regarding community and employee safety measures, an Energy Resilience Readiness Exercises (ERRES) exhaust system with a charcoal filter was integrated into the lab infrastructure. This system serves as a safeguard in the event of potential hazards, ensuring that any toxic fumes or chemicals are effectively filtered, preventing their release into the exterior environment. This precautionary measure was specifically designed to address emergency situations or accidents involving lab equipment, explosions and fire.

Hexcel Corporation Center of

Research & Technology Excellence

Owner: Hexcel Corporation

Cost: $34 Million

Delivery Method: Design-Build

Stories/Levels: 2

Square Footage: 105,000

Design Team
Architect: Architectural Nexus
Civil: Wilding Engineering
Electrical: Hunt Electric
Mechanical: CCI Mechanical
Structural: Dunn Associates, Inc.

Geotech: Wilding Engineering

Interior Design: Architectural Nexus
Landscape Architect: Architectural Nexus

Construction Team

GC: R&O Construction
Plumbing: CCI Mechanical
HVAC: CCI Mechanical
Electrical: Hunt Electric

Concrete: Phaze Concrete
Steel Fabrication: Sanpete Steel
Steel Erection: Sanpete Steel; Unlimited Steel
Glass/Curtain Wall: LCG Facades
Drywall/Acoustics: K&K Drywall Inc.
Painting: Fisher Painting
Tile/Stone: Spectra Contract Flooring
Carpentry: Blue Stream Construction
Flooring: Spectra Contract Flooring

Roofing: Redd Roofing

Waterproofing: Western States Waterproofing
Excavation: Reynolds Excavating
Landscaping: Waterscape Landscaping

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