F/A-18 Corrosion Control Facility

Location: Marine Corps Air Station, Beaufort, S.C.

Client: NAVFAC, Southern Division

Completion Date: 2001

Burns & McDonnell completed comprehensive design-build services for the F/A-18 Corrosion Control Facility at Marine Corps Air Station (MCAS) Beaufort, S.C. As the prime contractor, Burns & McDonnell was responsible for overall project management, facility design, construction, commissioning and turnover of the facility.

Design was phased with construction on a fast-track schedule and was completed in November 2000. Construction commenced in September 2000 and completed in October 2001 on schedule with less than 0.03% cost growth.

The 22,000-square-foot facility includes three bays to support aircraft painting operations and related shops, storage and administrative areas. The facility is a steel-framed pre-engineered structure with a split-faced CMU wainscot, prefabricated metal insulating wall panels and metal standing seam roof.

Two of the three bays include an industrial ventilation system capable of providing laminar airflow across the aircraft at a constant velocity of 50-fpm conforming to MIL-HDBK 1028/1C and Subpart Z of 29 CFR 1910. Process air is introduced into each bay through full-width plenum doors at approximately 85,000 CFM, drawn through the paint bay and a 3-stage dry filtration system at the rear of the bay, and exhausted by explosion-proof fans into the outside atmosphere meeting NESHAP emission standards. The third bay is utilized as an aircraft wash and preparation bay and capable of providing six air exchanges per hour to meet ventilation requirements. A support facility is located directly behind the hangar and houses administrative functions, paint storage and mixing areas, classroom and ready room/break room.

The fire protection system for the hangar complies with MIL-HDBK-1008/C and NFPA 409 and includes an overhead wet-pipe system with an underwing AFFF system activated by UV/IR sensors in each bay. AFFF waste is collected by the floor drain system and diverted from the oil water separator to a concrete retention basin at the site. Other mechanical support systems include breathing air, compressed shop air and hot water wash systems.

Electrical systems include exterior primary distribution, interior secondary distribution, 400-Hz power distribution systems, aircraft grounding, lighting, fire alarm, CCTV and LAN systems. Site work included a new taxiway connected to the existing taxiway, vehicle parking lot, security fencing and site utilities.