Aircraft Maintenance Hangar Upgrade, Iowa ANG

Aircraft Maintenance Hangar Upgrade, Iowa ANG

Location: Sioux City, Iowa

Client: Iowa Air National Guard

Completion Date: 2005

Burns and McDonnell completed A/E design and construction phase services (Type A, B and C) to upgrade and renovate existing operations and maintenance facilities for the 185th Fighter Wing at Sioux City, Iowa, to convert its operational mission from an F-16 Fighter Wing to a KC-135 Refueling Wing. This major change in the 185th’s mission required the renovation and upgrades to five major buildings along the flightline. Comprehensive services included asbestos surveys, roof sampling and analysis, geotechnical investigations and final reports, force protection analysis of buildings, on-site condition assessments, permitting and cost estimating.

The hangar upgrades and addition required major building renovations and additions to fully house the KC-135 aircraft and new aircraft shop areas. The hangar addition includes more than 13,000 square feet of high-bay area and the addition to the shops included more than 7,000 square feet to accommodate machine, structural repair and sheet metal fabrication shops. The addition expanded the existing maintenance bay and provided connection to the existing building at the area of the main doors. The existing hangar doors and operators were be removed and replaced with new horizontal sliding, traction-type door leafs and a new tail door was installed at the apron side of the addition. The hangar modifications included two new exterior building additions, one interior addition within the existing hangar bay, limited remodeling on the second floor and major remodeling on the first floor.

A new under-floor heating system consisting of a steam-to-water heat exchanger, heating water pump, in-slab piping and controls was provided. Two steam unit heaters were relocated to provide additional space heating in the hangar addition.

A wet pipe sprinkler system serves all areas of the building. The existing AFFF storage tank and AFFF monitors in the hangar were removed while the existing fire pump, jockey pump and fire pump controller remained to provide water for the hangar high-expansion foam fire suppression system. The high-expansion, low-level foam fire suppression system included 12 foam generators and bladder type tank for foam storage. In addition, electrical modifications included upgrading existing 400-Hz and 208Vdc systems to serve the new aircraft. 

Sitework included approximately 350 feet of 8-inch sanitary sewer and 250 feet of 10-inch ductile iron water piping was removed and relocated outside the area of the hangar expansion and 8,000 square-feet of apron added to the front of the hangar.

During construction, Burns & McDonnell provided full-time on-site construction representation services as well as comprehensive engineering services for submittal reviews, periodic engineering inspections, and final closeout documents. Cost: $10.3 million.