The Salisbury Regional Airport (SBY) identified a parcel in their airport business park, at the end of Taxiway G as the ideal location for an experimental drone testing and certification project, as a part of the economic strategy to attract more Unmanned Arial Systems operators to the airport. The Airport selected Harper & Sons as the Design-Builder for the project site and building construction, based on the team’s civil, building, and aviation experience.
The project faced some key challenges immediately. The site was closely bordered by non-tidal wetlands, had marginal soil profiles at the surface, and had no existing utilities nearby. The building needed to be tall enough to handle much taller aircraft than drones (to be flexible for future jet aircraft), yet needed to minimize the width to fit on the site.
Harper & Sons design-team opted for a minimal site foot-print, creatively treating quality and quality of storm water, and skillfully navigating the regulatory approval process without multiple design revisions. The team designed and installed a pump station and low-pressure force main, connecting to the municipal gravity sewer, more than a quarter-mile away. The water was handled by installing a drilled well, but underground water utilities were installed for future connection to the municipal water system which was slated for expansion. The fiber and electric utilities were directional drilled beneath the wetlands to minimize ground disturbance.
The marginal soils were resolved by an engineered soil cement application beneath the taxiway extension, new apron, and parking lot. Because the project was started late in the year, the building pad soils were also supplemented with soil cement to prepare the subgrade for the slab and maintain the schedule.
The building challenges were overcome by a 34’ eave building, with an 80’ x 27’ bi-folding aircraft door. This minimized the width of the building (compared to a bottom-rolling door) and allowed the maximum wing-span and tail-height for future non-drone vehicles to use the hangar. The door was transported to the site in 4 sections, assembled, lifted into place, and final welded.
Finally, given the low site profile, the building floor slab received a moisture-breathing aviation-grade epoxy floor system, to mitigate any potential moisture issues.
The construction included office fit-outs for drone testing, drone control rooms, collaboration spaces, kitchen, and restrooms. Two large walk-out mezzanines allow viewing and storage in the hangar space.
As a bonus challenge, during the project, the Airport asked Harper & Sons to refurbish, repaint, and erect a new AWOS tower adjacent to the drone hangar! Harper & Sons jumped at the opportunity, and completed the task, including designing the foundations, installing airport lighting, and new electoral systems on the tower.
The project’s success did not go unnoticed, as the ribbon cutting was attended by state, county, and local officials; and by economic development teams from more 4 counties!
Services: Design-Build Site Development & Building Constuction
Quick Notes
- Location: Salisbury, MD
- Building SF: 7,480
- Design: George Miles & Buhr, Inc.
