Dassault Falcon Jet Melbourne

Overview 

Dassault Falcon Jet’s new state-of-the-art service complex in Melbourne, Florida, marks a major expansion of its global maintenance, repair and overhaul (MRO) network. The facility will support all current Falcon models, including the Falcon 10X, and will be capable of servicing up to 18 aircraft simultaneously. 

We assisted with the erection engineering of the primary structural steel frame. The facility will also include a 54,000-square-foot paint shop and offer everything from minor repairs to full overhauls, with on-site customer amenities.

Highlights 

• We reviewed the temporary stability of the steel structure during erection, including column stability, required column pipe braces with helical ground anchors, temporary bracing plan and truss erection sequence plan.
• We also reviewed the temporary stability during lifting and erection of hanger door trusses with multiple spans up to 225 feet and 120-inch-deep steel joist girders.
• The hangar door header truss spans 225 feet across the door opening and was erected in two sections. It is supported by a central custom shoring tower. We provided review of the truss stability during lifting, including design of the custom shoring tower, jacking base and foundation.
• Front-to-back, 120-inch-deep joist girders have a clear span 130 feet between the back wall and header truss. The roof was erected with four panelized joist kits between joist girders to stabilize joist girders during erection. A joist kit was made up from a pair of 24K joists with decking and bridging installed, and temporary angle lacing.
• We provided a sealed erection procedure with detailed 3D views of the step-by-step erection sequence and provided minimum bolt-up requirements for the field crew at each step of erection.