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From wingtip to cockpit – 800 workers in 80 days

August 22, 2014 Aviation No Comments Email Email

It takes 800 workers just 65 to 80 days to assemble, install, test, paint, furnish and deliver an Emirates Airbus A380, the iconic double-decker aircraft that has been creating headlines and delighting travellers since it first entered into service in 2008.  

It takes 800 workers just 65 to 80 days to assemble, install, test, paint, furnish and deliver an Emirates Airbus A380, the iconic double-decker aircraft that has been creating headlines and delighting travellers since it first entered into service in 2008.

Click here to watch a time lapse video on the making of Emirates’ 50th A380 aircraft which was delivered last month.MSN_154_TakeOff_Ferry_Credit-Airbus-_4_

Emirates operates the world’s largest fleet of A380 aircraft, with 50 of these graceful feats of modern engineering currently serving 29 global destinations. All of Emirates’ A380s have been furnished and delivered via the Airbus facility in Hamburg.

First, the aircraft fuselage is produced in Hamburg and then transported to Toulouse for the first stage of final assembly. The wing sections, produced in the UK, are also shipped from Airbus’s Hamburg facility to Toulouse. Parts like the fuselage and wings are transferred through a transportation network that includes three specially-commissioned ships to carry the sections from production sites throughout Europe. Over 10,000 bolts are used to connect the fuselage and over 4,000 for the wings.

The first part of final assembly, which takes place in Toulouse, yields an aircraft that is ready for its first ferry flight, sans its interior and paint.

After assembly, each of the five sections of the fuselage are tested by engineers, and then the aircraft is off to Hamburg for painting and cabin furnishing. It takes 30 people approximately 10 days to paint the A380, which has a surface area of 3,150 square meters – approximately the size of seven professional basketball courts. Over 500 kilogrammes of paint is needed just to give the aircraft its white colour.

Cabin furnishing, to install Emirates’ distinctive on-board facilities come in the final stages of the assembly process.  It takes about 33 working days to furnish the 550 square metre cabin area on-board the Emirates A380. This includes all seats, galleys, crew rest areas, the unique shower-spa and private suites in First Class, the on-board lounge located at the back of the Business Class cabin, and the award-winning ice inflight entertainment system in all cabins.

Emirates received 13 of the giant double decker aircraft in the last year. Over 28 million passengers have travelled on the Emirates A380 over the last six years of operations, and more travellers can look forward to the experience as Emirates adds more A380 destinations to its route network. New A380 destinations planned for this year include: Frankfurt on 1st September, Dallas on1st October, San Francisco on 1st December and Houston on 3rd December.

The Emirates A380: Quick Facts

Total number of passenger seats (Emirates has two A380 configurations) 489 / 517
First Class 14
Business Class 76
Economy Class 399 / 427
Number of A380s in Emirates fleet to date 50
Number of A380s pending delivery 90
The shortest flight on an Emirates A380 (destination, distance, duration) Dubai-Kuwait, 851 kilometres, 1 hour 45 mins. This is also the world’s shortest A380 route.
The longest flight on an Emirates A380 (destination, distance, duration) Dubai-Los Angeles, 13,414 kilometres, 16 hours 20 mins. This is also world’s longest A380 route.
Number of channels offered by ice, Emirates’ inflight entertainment system in all cabin classes > 1,800 channels on-demand
Number of bottles of wine on board a typical Emirates A380 flight 478
Number of bottles of champagne on board a typical Emirates A380 flight 31
Number of bread rolls loaded onto an A380 650 for all three classes
Number of croissants on board an A380 Up to 550  for all three classes
Number of main courses served on an A380 Approximately 515 for all classes
Number of desserts served on an A380 Approximately 450 for all classes
Number of sandwiches loaded for the A380 Onboard lounge Almost 80 sandwiches
Amount of liquid soap loaded on Emirates A380 flight to Heathrow 12 litres of liquid soap distributed in 15 toilets
Volume of water that the aircraft holds to facilitate the showers 2,267 litres
Average number EK crew aboard each A380 flight (ultra- long haul flights) 4 flight deck crew, 24 cabin crew, 2 cabin service attendants

 

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