Oldcastle Precast constructs first-of-its-kind all precast air station hangar

BARTOW, Fla. – Oldcastle Precast announced today that it has completed work on the "first-of-its-kind" U.S Coast Guard air station hangar project which included a 20,000 square foot CAT 5 Aircraft Hangar, HAZMAT Storage Building, and Residential Building Structure for the U.S. Security Forces. The new CAT 5 aircraft hangar was constructed from the ground up using Oldcastle Precast’s new "Titan Wall" system. The entire aircraft hangar structure including the patent pending, motorized hangar doors, was fabricated using engineered precast concrete. The new facility allows the USCG to base helicopters and aircraft flying in support of OPBAT on Great Inagua, Bahamas replacing a previous steel hangar destroyed by Hurricane Ike in September of 2008.

The U.S. Coast Guard was seeking, low maintenance, extended lifecycle structures designed to withstand extreme weather conditions and requested a concrete structure in their specifications to meet those requirements. Oldcastle Precast’s new Titan Wall System was the product of choice and was selected over nine other bids due to its unique design and performance capabilities.

Titan Wall precast concrete solution
Driven by the challenge to create a large industrial structure capable of withstanding hurricane force winds, the Titan Wall precast construction system was developed through a unique combination of column panel construction, vertical foundations, and high strength, 6,000 psi precast concrete to provide a precast structure solution designed for wind loads of 180 mph.

Using this new system, Oldcastle Precast located in Bartow, FL engineered, manufactured, shipped and erected the precast structural components that made up the CAT 5 aircraft hangar. All structural components were designed and engineered to comply with the current editions of UFC 4-010-01 DoD Security Engineering Planning Manual and UFC 4-010-02 DoD Minimum Antiterrorism Standoff Distances for Buildings.

The CAT 5 hangar was constructed using (44) precast columns, over half of which exceeded 38′ high, and (200) 16′ x 8’ horizontal wall panels.

A total of (4) precast hangar doors were used to close the 28′ h x 125′ w hangar door opening. Each 28′ h x 31′ w door weighs 60,000 pounds, is composed of three precast panels sections, and is propelled individually which allows total flexibility for deployment. Each door also has two wheels; each wheel having its own motor allowing for total independence of movement.

Oldcastle Precast Titan Wall hangar doors were selected for their strength and their designed ability to prevent uplift from extreme wind forces, as well as through penetration from flying object or debris.

In addition, Oldcastle Precast constructed the 1,100 square foot precast HAZMAT building designed to house hazardous materials, fire pump equipment, and a 1,080square foot, four bedroom, two bath residential precast structure for Coast Guard staff. Both building structures were engineered to withstand extreme weather conditions.

Never before utilized in the aviation industry, the precast concrete hangar and door system demonstrates how Oldcastle Precast meets engineering challenges with new and innovative engineering solutions. Oldcastle Precast started production of this design-build project in October of 2011, erection started the following month in November and completed in mid-March 2012.

Construction Management of Florida Inc., located in Vero Beach, FL. was the 8(a) Prime Contractor and Design Builder on the project. Leo Daly is the designer of record and Bryan Construction, located in Colorado Springs, CO. was the subcontractor.

The U.S. Coast Guard has submitted this project for USGBC LEED-NC Certification.