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Rolls-Royce Aero-Engine Disc Factory

Transforming a former Dunlop Tyres factory into state-of-the-art aero-engine disc facility

Exterior of Rolls-Royce factory against a blue sky



Washington, Tyne and Wear, United Kingdom




Bond Bryan Architects

The £30m construction investment by Rolls-Royce allows the relocation of the 200,000ft2 Rolls-Royce aero-engine disc factory from Pallion, Sunderland, to a new plant on the site of the former Dunlop Tyres factory in Washington. The new site sees the continued redevelopment of the former Dunlop Tyres site, which has been returned to industrial use following its closure and demolition in 2006, ensuring the 60-year manufacturing history of the site is continued.

The new manufacturing premises incorporates production space, 38,000ft2 of offices, ancillary areas, a gatehouse, security, car parking, plant areas, landscaping and designated areas for deliveries and distribution by large vehicles. The facility has provision for future extension, and initially will be manufacturing more than 2,000 fan and turbine discs each year.

Alex Carter, Structural Engineering Partner, commented "As part of our diverse portfolio of Rolls-Royce projects, our teams in geotechnical, civil, structural design, and MEP disciplines collaborated to deliver this aero-engine disc facility. We produced an outline and detailed plan input, achieving a cost-effective, top-tier industrial production facility, revitalising former industrial sites, constructing buildings for jet engine production and maintenance."

Key fact

This project, designed and built with the aid of BIM, was a fast-track construction programme where collaboration and teamwork were key.


Key fact

The structural frame solution evolved from the original Rolls-Royce scheme, integrating complex trussed rafters with Westok beams for service distribution, crane support, and reduced building height.


Alex Carter in shirt with office interior background with glass feature

Alex Carter

Partner, Structural Engineering

View bio

We collaborated with Rolls-Royce in the design phase to understand and meet their precise requirements, ensuring minimal differential settlement across the new structure and floor slab, standing as a critical benchmark of success.