This project exemplifies the innovative application of mass timber construction in designing and building a cutting-edge aircraft hangar. Featuring a remarkable 210-foot free-span truss system and curved lenticular trusses, this hangar seamlessly blends structural integrity and architectural elegance to meet modern aviation demands.
The project leveraged precision-engineered connection systems to optimize installation efficiency. Screw cross-connections were employed to ensure a robust and adaptable assembly, allowing for on-site adjustments to accommodate the unique challenges of long purlins. With the ability to install purlins in just 8 minutes each, these solutions facilitated the rapid bracing of trusses, ensuring stability during construction. A screwing template further streamlined the process, eliminating the need for CNC machining and accelerating the timeline for over 300 purlins.
Key design challenges included integrating a horizontal bottom chord into the curved truss system and ensuring compatibility with the large steel hangar doors. Innovative 3D connections and slotted systems were developed to manage deflection and load transfer, preserving structural integrity under varying conditions. During construction, the 210-foot trusses were pre-assembled on the ground and lifted into place, requiring meticulous coordination and engineering to address low stiffness prior to vertical placement.
Completed in under three months, this project showcases an impressive balance of speed and precision. The hangar was also designed with sustainability in mind, contributing to the client’s goal of achieving a net-zero emission facility. Delivered on time and exceeding expectations, the hangar has set a benchmark for mass timber construction in aviation. The client’s satisfaction is evident in their decision to replicate the design for another location, highlighting the project’s success and potential for future innovation. Finally, this hangar is not only a testament to the possibilities of mass timber but also a shining example of how thoughtful engineering and streamlined construction practices can achieve extraordinary results.
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