Hangar 56-G was a fast track project to convert an existing Boeing 747-8 three bay aircraft production hangar into a new top secret aircraft production facility for Spirit Aerosystems. It includes aircraft fabrication, tooling and testing shops as well as calibrated isolated equipment operations slabs and hyper level floor slabs to accommodate specialty production and transfer equipment within the facility. The design required modification of the structural frame in several locations for the movement of specialized production tools through
the fabrication process. Moreover, one hangar bay was converted into a new high bay clean room production area with positive atmospheric pressure and a moisture controlled environment.
The original hangar building floor which sloped with the existing grade 4’+/- from end to end had to be converted to a new hyper level factory floor for the movement of large aircraft tooling equipment and production assemblies. The clean room production area included three 40-ton overhead bridge cranes to move parts between fabrication areas. The other two hangar bays were converted to additional factory spaces also including overhead cranes and moisture control systems. Along one side of each hangar bay, existing storage, tooling and production mezzanines and service lifts were modified to accommodate the coordination of production zones with the high bay areas. Three separate existing two-story office areas located within the footprint of the three hangar bays were renovated to accommodate the new production operations and engineering staff. The top secret security criteria encompassed both the exterior and interior building envelops by inhibiting visibility, and radio wave penetration as well as acoustical separation between testing zones, and special security hardware at all entries.
Three bay hangar 258,000 SF
Mezzanine service area 28,000 SF
Offices (two-story) 72,800 SF
Total: 359,200 SF