Vero Beach (Florida) Regional Airport T-Hangar complex rehabilitation

Project Summary

The city of Vero Beach retained Hanson for assistance when maintenance costs markedly increased for the T-hangar complex at Vero Beach Regional Airport.

The T-hangar complex consists of six sets of hangars that encompass 13 large, executive box hangars with door openings from 46 feet to 49 feet and door-operating systems, including electric bifold and manual accordion styles. The complex includes 28 small T-hangars with 39-foot manual sliding doors and eight medium T-hangars with 46-foot electric, bifold doors.

“The Hanson team that we have worked with here at VRB speaks our language. Hanson personnel have experience as airport managers, pilots, state aviation agency representatives and, of course, engineers. They have productive relationships with regulatory and funding agencies alike. That background of talent and experience has served us well, and we anticipate that trend to continue moving forward.”

Todd Scher, Vero Beach Regional Airport director

Among the problems the airport staff reported were structural failures to the roof purlins and I-beam door frames, which prevented the doors from fully closing. The roof and wall purlins also experienced structural failures that loosened the hangar skin. The electric bifold door system, which operates on a dual motor and cable system, also had cable fraying and breakage that caused the motors to operate out of synchronization, jamming doors and breaking cables. Additionally, the dual motor system required a section of the cable roller system to extend through the access door, resulting in trip-and-fall injuries. The door lock pin system for the sliding doors for security and heavy wind load (hurricane) protection was missing because it was not affixed to the door. Other issues included numerous areas of corrosion.

Hanson was retained to evaluate the T-hangar buildings and determine needed repairs. The evaluation included a structural analysis of the buildings, an evaluation of the bifold hangar doors for replacement with a dual motor strap system and an evaluation of hangar sheathing and roof structures. Hanson completed the inspections and provided a report detailing the evaluations, deficiencies and recommended repair options and provided a life expectancy of the buildings with the recommended repairs. 

After reviewing the report, the airport’s staff retained Hanson to provide bidding documents to incorporate the recommendations and provide inspection services during the project's construction.

During construction and inspection, the airport’s staff requested that Hanson work with the contractor on a quote to replace all locks on the hangar’s “main ” doors with a system that would provide individual locks for each door and a master key for the entire hangar system.  

The project required a significant amount of coordination with the hangar tenants, airport staff and contractor so that aircraft could be moved out of the hangars to prevent damage or obstacles during construction. Hanson also designed a new sliding door pin lock system that would remain attached to the door, making it easy for tenants to use.