Aeroman Aircraft Maintenance Facility
El Salvador

Size: 118,000 SF

Construction Cost: $11.7 Million

2008 ACEC Washington State Chapter Gold Award

Wood Harbinger provided mechanical, electrical, and fire protection engineering to develop a new Aircraft Maintenance Hangar and Shop Facility. A full week Design Charrette evolved the project from a two-bay maintenance hangar to a multi-phased facility master plan. The total build-out is planned to include twelve 118,000 SF heavy maintenance hangars to service Boeing 737, 757, and Airbus A-320 aircraft, a central energy plant, a warehouse, a facility maintenance center, staff training facility, cafeteria, locker rooms and recreation, and facility management offices.

Phase 1 was the first twin-bay 118,000 SF hangar, which included sheet metal, sanding, composite repair, painting, seat repair, and component repair shops. The hangar is served by a 1.5 MVA, 44 kV/480 V substation, three 90 KVA 400 Hz aircraft power supplies, and a central services area that provides shop tool compressed air, aircraft pneumatic air, aircraft cabin cooling, and high pressure hydraulic oil for aircraft systems operations.

Energy efficiency was achieved by incorporating a unique set of electrical and mechanical features that promote optimal lighting and natural ventilation. A translucent roofing membrane eliminates the need for electric lighting during daytime operations. For operations during non-daylight hours, a precision gallery of light fixtures is strategically directed at points of the hangar, illuminating critical areas to maximize effectiveness and consuming 30% less energy than traditional overhead grid systems.

The translucent membrane roof, in combination with the vertical lift doors and air-induction chimneys, cool the occupied areas of the hangar naturally and economically. These features produce a constant stream of air movement that is focused at the hangar’s ground level. In the hot, humid climate of El Salvador, this airflow significantly increases worker comfort and productivity. In addition to contributing to the cooling of the hangar, the vertical lift doors also contribute to worker safety by preventing bird infiltration, a rampant problem for many Salvadoran structures.

“Model of efficiency in the aviation Maintenance, Repair, and Overhaul (MRO) community.” – Ernesto Ruiz, Aeroman CEO