Flightline Replacement Facilities

Location: Rota, Spain

Client: U.S. Navy

Burns & McDonnell completed final designs for five facilities to support expansion of airfield and fueling system at the Naval Station in Rota, Spain. These facilities included a light aircraft maintenance hangar, morgue, refueler maintenance facility, AMSS FSL warehouse and maintenance facility, and fleet mail facility.

Each facility is a steel-framed structure with metal deck and standing seam roof. The exteriors are a combination of masonry and metal insulating panels. The buildings provide for shops, workspaces, specialty work areas, conference rooms, toilets, locker rooms and offices. Total floor area is approximately 43,000 square feet.

Each facility was designed to meet current Department of Defense and European Command Antiterrorism and Force Protection standards. Burns & McDonnell implemented several LEED® elements to support the Navy’s sustainable design practices. The project provided for extensive modifications to the base infrastructure and utility systems.

Burns & McDonnell also provided assistance with environmental permitting. A fuel containment and discharge system to capture any catastrophic release of fuel from refueler trucks was also provided. Wet pipe, dry pipe and AFFF preaction fire protection systems were used throughout to project depending on the application.

The project included design of a USAFE Type III hydrant refueling system, including designs for an operations building and fuel storage and delivery systems. The operations building is a single-story facility that provides shelter for the filter separators/fuel monitors and flow/pressure control equipment, the electrical substation, emergency generator and the control console that permits manual or automatic operation of the fuel system.

The fueling facility features two 10,000-barrel cut-and-cover fuel storage tanks. Both tanks have splinter-protected structures on top that house dual vertical turbine pumps, level controls, tank fill connections, flow prevention devices and a tank leak-detection sump pump. The pump control and annunciation system consists of a dual, hot-backup, programmable logic controller system. A cathodic protection system was added to and integrated with the existing system at the fuel tank farm. All underground storage tanks and underground fuel piping were protected using an impressed current system. The fire alarm system consists of a multi-zoned, nonaddressable system that monitors the operations building, the pump vaults and the jet fuel storage tanks.

Also provided were connections to existing refueler loading positions, five in-apron hydrant pits at planned aircraft parking positions for C-5A, DC-10, KC-135, C-141 and C-17 aircraft, three dual-range stainless steel portable pantographs, two high-reach portable pantographs and modifications to six existing mounded 5,000-barrel ready/issue tanks.