Construction of a 225,000 s.f., LEED Silver Certified service center aircraft hanger at Phoenix-Mesa Gateway Airport.

This facility was designed and constructed to store materials used in the production of aircraft and aircraft components. Because these materials were hazardous, the storage areas were divided into four distinct zones to prevent the mixing of incompatible chemicals. A laboratory was included to test materials for remaining shelf life, ensuring compliance with all EPA requirements. Materials are inventoried and retrieved using robotic lifts, which required super-flat tolerance for all concrete floors.

This facility was designed and built to manufacture various aircraft parts on an emergency basis while planes are grounded due to mechanical failures. The building included a 20,000-square-foot mezzanine for engineering, design, and manufacturing staff. Part designs were transmitted to the manufacturing floor through a fiber-optic-driven CAD/CAM system. After production using over 500 machines, the parts were coated in the tank farm and spray booths through dipping and spraying processes.

This facility was designed and constructed to provide steam to superheat the interior environment of the paint hangar during the paint curing process. When there was no demand for steam heat, the two Babcock & Wilcox boilers redirected output to two large steam-driven turbines that generated power and fed it back into the plant’s electrical grid.