Aviation & Transportation Structures

In large-span structures the structural system choice drives tonnage. We compare trusses, space frames and arched or cable-assisted options for the required clear span and door width, then refine member depths, panel geometry and camber to reduce weight. Standardizing truss modules and node details shortens fabrication, and early coordination of roof-hung equipment avoids late strengthening. For terminals, we align the grid with architectural and baggage-handling layouts to limit transfer structures.

Typical members include deep built-up header girders, heavy truss chords, tubular or open-section web members and space frame nodes. Full-penetration welds in chords and splices are made to the AWS D1.1 or EN 1090 execution class specified, often EXC3 for critical long-span elements. Camber is built in during assembly and verified before release.

Where geometry is complex, we carry out trial assembly of truss segments or header splices in the shop to confirm fit and camber, then match-mark pieces for site assembly. Bolted splice plates are drilled in assembly where accuracy demands it, and segment ends are protected for transport. This shop work transfers the hardest geometry control away from the airfield, where access windows and crane time are limited.

Our inspection and test plan for aviation structures includes hold points for critical welds, camber checks and trial assembly. Material is traced to mill certificates, with impact-tested grades where the specification requires them. Full-penetration welds receive ultrasonic testing, and fillet welds receive visual and magnetic particle inspection at the specified frequency. Dimensional surveys record truss length, camber and splice alignment, and everything is compiled in a QC dossier issued with each shipment.

Hangar interiors are usually moderate environments, but airports near the coast or with de-icing chemical exposure can reach C4 or C5 under ISO 12944. We specify paint systems matched to the corrosivity and design life, with higher-performance systems on external door headers and canopy edges. Fire protection requirements for hangars and terminals are coordinated early, and intumescent coatings are selected for compatibility with the primer and the desired finish in public areas.

Long-span members must be broken into transportable segments without compromising the structure. We define splice locations during design, then pack truss segments, space frame nodes and members in sequence by erection zone, clearly tagged for the assembly area. Oversized header girder segments are shipped as break-bulk with engineered supports, while standard members travel in containers. Export documentation, packing lists and lifting data for heavy pieces are provided with each shipment.

Erecting long spans near live airside operations demands careful planning. We provide erection drawings, assembly geometry for ground-level truss assembly, lifting weights and centers of gravity, and temporary stability checks to support the erector's method statement. Our engineers can advise on lift sequences, temporary supports and camber verification. Where agreed, we provide technical supervision during critical lifts and door header installation.