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Balfour Beatty Construction Completes MV-22 Double Hangar Project at Marine Corps Air Station, Camp Pendleton
March 21, 2016
Challenging design-build project successfully achieves the largest single steel erection on base
with 200,000 man hours and zero lost time Incidents
SAN DIEGO – Balfour Beatty Construction has completed the $38 million design-build MV-22 Double Hangar project located at Marine Corps Air Station (MCAS), Camp Pendleton in California. The two maintenance hangars each accommodate six MV-22 Osprey, which are tiltrotor military aircraft and the primary assault support aircraft for the U.S. Marine Corps.
The project scope included the design and construction of a new, 123,451-square-foot, two-bay hangar with state-of-the-art specialty maintenance shops, administration offices and training/mission planning accommodations, as well as the demolition of an existing hangar. Design services were provided by KMA Architecture.
Completed in 21 months, the project was designed to obtain a LEED® Silver rating from the United States Green Building Council. Sustainable features include a photovoltaic parking structure with solar panels that will provide 30 percent of the energy to the facility, 100 percent backup emergency generator power, skylights in hangar bays, and a cool roof system which requires less energy consumption during the summer.
The work included the erection of two, 475,116-pound, 10-foot tall, 20-foot wide, and 340-foot long steel truss sections, as well as the supervision of over 50 trade partners that collectively logged 200,000 man hours with zero lost time incidents. The two box steel truss erection is the largest single steel erection at MCAS—the approximate assembled length of each truss is the length of a football field plus 40 feet.
“To achieve our goal of zero lost time incidents on this demanding project required a laser-like focus on our Zero Harm culture in addition to exceptionally thorough planning and preparation,” said Dan Chandler, project superintendent at Balfour Beatty Construction. “Challenges we faced required detailed safety logistics plans to address potential hazards, including demolition of the previous 60-foot tall hangar. Culminating with the two-day truss erection, the team bolted four 80-foot sections together and used two cranes in unison to move each truss into position. An effort this complex required tight integration among everyone involved and we’re very proud that we had the opportunity to deliver this project for the U.S. Marine Corps.”
Luis Adrianzen, Marine Corps Air Station Public Works Division project leader, gave the team high marks for the truss erection. “The project team remained diligent throughout the process to ensure that every individual involved was included in the planning process – from the manufacturing to the deliveries and the erection process. All of the pre-planning paved the way for a successful and flawless product with zero safety issues. The event was impressive in size and magnitude, while the process went seamlessly, with little to no intrusion on the daily operations.”
“The military takes safety very seriously and even as diligent as they are, they were extremely impressed by what we were able to accomplish on this project” said Mark Chappell, senior project manager at Balfour Beatty Construction. “We did it as a team with everyone on site taking on the role of a safety and health leader, even our project accountant and field engineer. We all took our responsibility very seriously and this is hands down the best project I’ve ever been on in terms of safety.”
“Working on an active flight line at a Marine Corps airfield is always interesting, and presents unique logistical and safety challenges,” said Sumeet Gadi, senior vice president at Balfour Beatty Construction who was in charge of the project site. “The thorough planning and intense preparation resulted in this project’s great success, and the team was more than ably led by Mark and Dan with indispensable support and contributions by our quality control manager, site safety and health officer, and project engineer.”