Accelerated aerospace facility expansion

Client & Context

L3Harris Technologies supports critical aerospace, defense and communications programs through advanced manufacturing and technology solutions. To expand its Palm Bay campus, the company commissioned a new 94,000 sq ft facility, dubbed Project LEO, designed to support satellite production and clean manufacturing operations.

Meeting the expansion project’s aggressive turnover requirements was essential. Any delays could jeopardize customer contracts and cascade through L3Harris’s production commitments — making on-time delivery as critical as the technical execution itself.

The Challenge

The facility’s multiple 70-foot-high bays required extensive work at elevation — a logistical challenge that demanded continuous momentum and disciplined sequencing to keep pace with the accelerated schedule.

Stringent security requirements added another layer of complexity. Every secure wall penetration required dielectric isolation, security bars and waveguides to protect sensitive operations from physical and radio-frequency intrusion. In a facility handling sensitive defense programs, a single compromised penetration could have implications far beyond the construction project itself. Getting it right was a requirement — and demanded precise coordination.

Our Approach

Corvant immediately followed structural progress with mechanical and plumbing installation, deploying 60- and 80-foot lifts to maintain momentum and accelerate equipment startup across the high bays.

The facility incorporated three 140-ton air-cooled chillers, four large air handling units, HEPA filtration, seven CRAC units serving critical spaces, compressed air and gaseous nitrogen distribution, exhaust and hydronic systems, and complete plumbing infrastructure — all coordinated within an active, high-security environment.

Through detailed planning and disciplined execution, Corvant coordinated extensive high-bay work while adhering to the facility’s stringent security standards at every phase — ensuring every element was correctly isolated, documented and approved before moving forward.

The Outcome

Project LEO was successfully delivered within the accelerated schedule, providing L3Harris with a fully operational facility — with every security requirement met and every system commissioned — ready to support the next generation of defense programs from the moment its doors opened.

The project deepened Corvant’s relationship with the owner and general contractor, while further demonstrating Corvant’s ability to execute complex aerospace and defense projects where schedule and precision are mission-critical.