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Project F-22 Heavy Maintenance Facility and Composite Back Shop

Project Size

105,232 sq ft

Project Dates

25 months

Project Location

Hill Air Force Base, UT

Hill Air Force Base (HAFB), the largest military base in Utah an a key strategic center for the U.S. Air Force, needed up-to-date space to repair and maintain its fleet of F-22 aircraft. Big-D helped them develop a large workspace with maximum flexibility.

  • Self Performed Structural Concrete
  • BIM
  • “Outstanding” final performance evaluation from USACE
  • Best Portland Concrete Pavement Military Airport Project completed in the State of Utah | American Concrete Pavement Association, Utah Chapter and the Utah Department of Transportation | 2011

Project Description

The design-build F-22 Heavy Maintenance and Composite Back Shop facility provides vital space for specialized composite fabrication and aerosystems component replacement unique to the F-22 fighter aircraft. The project is a 105,232-square-foot, single-story industrial production facility. The seven-dock, medium-bay fighter aircraft maintenance hangar includes aircraft support areas, equipment rooms, and administrative support addition to Building 674. Workers have access to a new media blast booth, paint booth, and five maintenance booths. Three maintenance booths can use inserts to convert to paint booths.

The site work included the demolition of an existing tow-way to Buildings 674 (F-22 hangars) and 680 (C-130 maintenance hangar). Big-D then installed a new, 75-foot-wide taxiway with 25-foot-wide shoulders on each side, using Air Force Medium Load Criteria for Traffic Area A per UFC 3-260-01 & 02, as well as three new aircraft tow-ways to the facility. Approximately 425,000 square feet of rigid PCC pavement and 300,000 square feet of flexible pavement were installed. Big-D also built a 11,950-square-foot, detached, steel-reinforced concrete fuel/de-fuel and purge pad able to accommodate two full-size F-22 fighter aircraft side-by-side.

The facility includes Anti-Terrorism/Force Protection features such as an effective building layout, significantly reduced opportunities for targeting building occupants, and window and door designs to minimize flying debris risks. This project incorporates laminated glazing and hollow steel doors and frames. This facility was built to UFC 4-010-01 standards incorporating mass-notification systems tied into the Hill AFB master system.

Although the facility is not currently LEED certified through the U.S. Green Building Council, we designed and built it to LEED Silver-certifiable criteria, according to LEED Version 2.2.