The Challenge:

Ryanair required a new hangar to support a diverse range of operational requirements in one location, including aircraft maintenance, training and ancillary services. The hangar would straddle both landside and airside environments and would connect to Stansted Airport’s existing aircraft taxi-way infrastructure. During the project, it was critical the airport remained fully operational and the construction phase would not impede the daily duties associated with running a busy airport.

The Solution:

Kier designed and constructed an aircraft hangar capable of allowing up to five Boeing 737s to undergo maintenance simultaneously. The rear of the structure would house three floors of Ryanair offices, workshops and crew training facilities, including flight simulators.

In total, the building measured 128.5m x 58.7m with a maximum height of 24.8m together with an adjacent warehouse facility measuring 54.4m x 31.0m x 14.7m. The building consisted of a structural steel frame with roof and wall cladding.At the airside entry, the hangar is accessed through a 123m wide door, which was largely regarded as the widest clear door opening in Europe at the time of opening.

The team worked closely with the customer and airport management to deliver the project within a critical live airside environment. Measures were taken to ensure the site was kept secure and the airport’s daily operations continued without interruption.

The Impact:

The project was delivered on time and in budget. The unique build of the hangar’s cavernous interior, which incorporated a 10m deep, single spanning truss structure received a UK structural Steel Design award.

In addition to the hangar development, Kier has completed numerous projects for Stansted Airport, including retail works, runway lighting, refurbishments, car park and signage upgrades, covering both landside and airside areas.

" This project is a fine example of an optimised long-span structure, at minimum cost with fast erection. A text-book example of this direct approach "
Judge at the UK Structural Steel Design awards

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