Our design-build team helped United Airlines navigate new California fire protection regulations by delivering accelerated upgrades across its nine-hangar maintenance facility. The project removed per- and polyfluoroalkyl substances (PFAS) by converting the existing aqueous film-forming foam (AFFF) systems to a fluorine-free foam (F3) alternative.

We involved a specialized fire protection subcontractor from day one and implemented a phased approach to avoid disrupting critical maintenance operations during the renovations and to meet the compliance deadline. Navigating a project of this scale within a maintenance facility operating 24/7 required innovative solutions focused on safety, value and efficiency.

Operational continuity: To avoid disrupting the airline's critical maintenance schedule, we negotiated with local authorities to allow work to continue under a vigilant fire watch. This eliminated the need for costly phased construction and allowed the airline to maintain its round-the-clock operations without interruption.

Cost savings: We found multiple opportunities to deliver significant cost savings without compromising safety. This included gaining approval to use black steel piping instead of more expensive stainless steel and justifying the removal of legacy hose reels. By providing a detailed engineering analysis, we documented that these alternatives would meet all safety and performance standards.

Compliance challenges: During design, our team discovered that existing systems did not meet modern codes. Rather than undertaking a costly full replacement of the distribution piping, our engineers developed an accepted performance-based design. This equivalency added foam concentrate to meet the required protection, achieving compliance and saving the client significant expense.

Efficiency gains: When existing fire pumps were found to be noncompliant, our team developed a more efficient fire pump design that met current standards while reducing the number of pumps from nine (2,500 gpm each) to five (3,500 gpm each) without changing overall system water demand.

Environmental stewardship: Our team was aware of falcon nesting on-site from the outset, so we planned the work to avoid impacts during nesting season and, when nesting was later confirmed, shifted construction to other hangars. Once the nesting and fledgling period was complete, we returned to those areas, keeping the project moving while protecting local wildlife.