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AIRBUS | FAL A321XLR – Ex-FAL A380 Refurbishing project

Missions

Airbus is converting the Jean-Luc Lagardère site (former A380 Final Assembly Line) to establish a new A321 Final Assembly Line (FAL) with an initial production rate of 10 aircraft, and provisions for future expansion to rate 20.

Client

AIRBUS OPERATIONS

Date

March 2022 - January 2026

Location

France

Creation of 2 new FAL (cadence 10 then Cadence 20)

  • Cadence 10 opened in 2023
  • Cadence 20 opens beginning of 2026

The project is divided into several Clusters:

  • Cluster 1.1: P44 to P35 – Main Assembly Line (Rate 10 → 4 stations: wing, fuselage, and systems assemblies over 12,500 sqm),
  • Cluster 1.2: 25,000 m² of ancillary areas for the main assembly line (workshops, logistics, workplaces, etc.),
  • Cluster 1.3: Energy retrofit of the “Arche” building to reduce the site’s overall energy consumption,
  • Cluster 1.4: L80 – Pre-assembly area (preparation of fuselage sections, PHR, vertical tails),
  • Cluster 2.1: P25 to P23 – Technical and commercial completion lines (40,000 sqm),
  • Cluster 2.2: P18 to P15 – Outdoor test areas (20,000 sqm),
  • Cluster 2.3: Weighing hangar (1 weighing position + 2 A321 working party positions) and paint preparation area,
  • Cluster 2.4: Fuel Station,
  • Cluster 3.0: 5 km connection road from the Beluga offloading zone to the buffer area at L80.

setec serige acts as the lead design office and prime contractor for all clusters (except Cluster 2.2).

Expertises

Technical project management

Challenges

  • Highly complex sub-slab networks and foundation systems,
  • Very tight project schedule,
  • Assembly tooling design studies carried out in parallel with on-site construction.

Key figures

Delivery Schedule

  • Cluster 1.1: May 2022
  • Cluster 1.2: March 2023
  • Cluster 1.3: June 2022
  • Cluster 1.4: April 2022
  • Cluster 2.1: February 2023
  • Cluster 2.2: May 2023
  • Cluster 2.4: May 2023
  • Cluster 2.3: April 2023
  • Cluster 3.0: June 2022

Surface Areas

  • Converted buildings: 70,000 m²
  • New ancillary facilities: 25,000 m²
  • Reconverted outdoor areas: 60,000 m²

Project Cost

  • €120 million