Low Observable Coatings/Composite Repair Hangar

Client: Langley Air Force Base
Completion Date: 2010
Location: Langley Air Force Base, Va.


Burns & McDonnell provided retro-commissioning services for the 41,500-square-foot Low Observable Maintenance/Composite Repair Hangar at Langley Air Force Base in Hampton, Va.

The hangar facility is used by the air base for the maintenance and repair of F-22 aircraft. Typical repairs include work on low observable coatings and aircraft composites. Facility spaces include two coatings/restoration bays, wash bays, paint preparation bay, composite preparation and cure areas, support areas, and personal administrative space.

Burns & McDonnell developed an initial retro-commissioning work plan detailing project-specific goals and objectives. The project work plan included team member expectations, means and methods for systems testing, deficiency reporting procedures, communication protocol for issue resolution, and ongoing operation and maintenance protocol for facility staff.

Functional testing of facility systems required a hands-on team effort from facility personnel, controls contractors and the commissioning team. System testing began with the initial evaluation of building equipment setpoints and operations. This information was compared to the intended operational sequences, and potential deficiencies were noted. After this initial review, team members began on-site testing and operational deficiency identification. After on-site testing, Burns & McDonnell assisted team members with guidance on deficiency resolution, discussed potential operational impacts with personnel, and made recommendations for prevention of problems.

The systems that were functionally tested during the retro-commissioning effort included chillers, boilers, air handling units, exhaust systems, and associated direct digital control (DDC) system and points. This testing effort included air and water system rebalancing, in addition to other controls modifications. During the testing process, special attention was given to maintaining the critical system airflows, temperatures and relative humidity tolerances required for aircraft maintenance.

The final retro-commissioning report included equipment functional test procedures, operation and maintenance documentation, preventative maintenance procedures and schedules, facility system operational schematics, previously identified deficiencies logs, deficiency solutions, and ongoing recommendations for facilities personnel.

These efforts facilitated by the Burns & McDonnell commissioning team resulted in 38% energy and cost savings, with a simple payback of less than one year.