UPS Hangar

overview

UPS expanded its operations in Louisville, Kentucky, through a long-term investment in its Worldport global air hub. The plan included new facilities to support its aircraft fleet and healthcare logistics services, contributing to job creation and regional economic growth. 

Supported by state economic incentives, the expansion reflected UPS’s ongoing commitment to strengthening its infrastructure and presence in Kentucky. This project, part of a $220 million initiative, was set to maintain UPS's fleet of 747 freighters. At the time of construction, it was the largest hanger being built in the United States. 

We provided construction engineering services to HME Inc., for the project, which includes the construction of a 155,000-square-foot, clear-span, single-bay, multi-position hangar; a two-story office and shop complex; and an engine and bulk storage facility. The hangar is able to handle two 747-8F aircraft simultaneously. 

Highlights 

• We provided full steel connection design, which included a 380-foot-long box truss.
• Additionally, we provided structural design for backup framing to support insulated wall panel cladding. Design included horizontal channel and sag rod cladding backup support connections to the primary structural frame. Design also included design of cold-formed metal framing wall systems.
• We provided peer review services to the general contractor for critical elements such as the massive hangar doors and the steel erection plan, which included strand jacking construction sequence for the box truss erection.
• We served as the construction engineer for the general contractor, providing review of subcontractors means and methods and loads imposed to the structure.