PROJECT

Hangar Expansion Program

We provided planning, programming, design and construction phase services for a new Southwest Airlines hangar at Phoenix Sky Harbor International Airport in Arizona. The clear-span, prefabricated metal building is certified LEED Silver. It accommodates three narrow-body aircraft and includes support space for offices, four shops — engine, welding, window and maintenance — and other maintenance support.

A key component of the program was meeting Federal Aviation Administration (FAA) airspace height limitations while still providing a clear-span space that maximized cost-efficiency and flexibility for aircraft maintenance.

We developed multiple site configurations and detailed construction schedules to assist Southwest in making programming decisions that balanced cost, schedule and impacts to operations. The initial programming showed a two-position hangar, but the design team was able to demonstrate that the facility could be reprogrammed, for a nominal investment, to fit three narrow-body aircraft. We also worked with the construction manager during conceptual design to collaborate with user groups on value engineering for facility materials and equipment.

Client

Southwest Airlines

Location

Phoenix, Arizona

Region

Southwest

Service

Hangars

Industry

Aviation

Integration on an Active Site

We coordinated closely with Southwest, the construction team, local airline personnel, city staff, utilities, airport staff and the FAA to provide detailed phasing plans to maintain operations of the existing hangar, active taxiways and utilities serving surrounding airport facilities.

The hangar site was already in use, requiring relocation of a provisions facility, ground support equipment (GSE) maintenance facility and a public roadway before construction. Partial demolition of the GSE structure, which was attached to an existing hangar, required integrated design support and observation. Detailed demolition plans were provided before and during demolition to see that safe operations continued in the existing hangar. Our team developed a creative approach to the phasing of demolition and relocation of these facilities to minimize impacts to operations.

Hangar Equipped for the Future

The 57,700-square-foot hangar with 25,700-square-foot support spaces includes state-of-the-art systems, including preconditioned air (PCA) at each aircraft with pop-up pits, compressed air along walls and within pop-up pits, 400-hertz ground power systems for each aircraft, LED lighting, a public address system, access control coordinated with an approved SIDA boundary, communications, closed-circuit television security, and overhead fall protection.

Overhead cranes serve the aircraft tail area, engine shop and welding shop. HVAC systems include evaporative cooling units with overhead radiant units and overhead industrial blade fans serving the hangar, packaged heat pump units with energy recovery for support spaces, and dedicated ductless split systems serving communications and electrical rooms.

Project Challenges

Planning

Programming

Architecture

Engineering

Construction phase services