SkyWest Airlines, which flies out of all major Idaho airports, will add an airplane maintenance facility at an existing Jackson Jet Center hangar at the Boise Airport and will decide by the end of the summer whether to add a larger facility in Boise.
SkyWest, headquartered in St. George, Utah, is a leading air service provider, and partner to some of the world’s largest network carriers including United Airlines, Delta Air Lines, US Airways, American Airlines and Alaska Airlines.
With a fleet of 346 aircraft, and a team of more than 10,500 aviation professionals, SkyWest operates approximately 1,900 flights each day to nearly 200 destinations throughout North America.
In September of 2014, SkyWest announced its intention to build a new aircraft maintenance facility at the municipally-owned Boise Airport in Boise, Idaho.
The $20 million project, which qualified for a $1.3 million Tax Reimbursement Incentive from the state of Idaho, consists of 100,000 sq. ft. of hangar space with 35,000 sq. ft. of office space.
Big D Builders, an Authorized Nucor Builder, worked closely with the City of Boise and SkyWest to assess customer needs and design a solution that meets expectations.
When the project is fully staffed, the economic impact to the state of Idaho will include new total wages in excess of $5.4 million a year and new sales and income tax revenues for the state of approximately $350,000 a year. The projected average annual wage is $52,000, well above the average in Ada County.
With a required clear span of nearly 400′, Nucor’s TrussFrame open web rafter system was a perfect fit for the SkyWest project.
Production began in July of 2014 at Nucor Building Systems’ Utah division.
The hangar boasts a clear span width of 362′ 4″ – the largest span in the Pacific Northwest region in a pre-engineered metal building – and is 365′ in depth. Its TrussFrame rafters, fabricated by Vulcraft, are 15′ deep, allowing for integrated mechanical, electrical, and sprinkler systems, as well as unimpeded overhead clearance of 62′.
The solid web columns supporting the TrussFrame rafter system are an imposing 10′ in depth.
Nucor Building Systems worked with hangar door manufacturer Norco to integrate their product seamlessly with the Nucor building, and meet the needs of the customer.
The building’s exterior is finished with Nucor’s CFR™ standing seam roof panels, and Nucor Reverse Classic™ wall panels.
In all, 1100 tons of Nucor steel went into the fabrication and construction of the SkyWest Hangar at Boise Airport.
The entire building project took less than sixteen months from concept to completion.
…In just 16 months, this project went from idea to ribbon cutting and I couldn’t be more proud of the partners who worked to pull it together. Bringing high paying jobs like those at this facility is one way we are working to make Boise the most livable city in the country.
Those in attendance at the opening included SkyWest’s Operations Manager, Mayor David Bieter of Boise, and Idaho Governor Butch Otter.
Marisa Snow, SkyWest Airport Director wrote on the Boise Airport website — “McAlvain Construction broke ground last October, completing the project in less than a year. The hangar is the largest pre-manufactured clear-span metal building in the Pacific Northwest.”
McAlvin touted the same on its website: “Earlier in 2014, SkyWest Airlines issued an RFQ to design/build contractors for its new Aircraft Maintenance Hangar to be constructed here in Boise, Idaho.” …
Similar to Kemp Construction’s approach, and for that matter every authorized Nucor Building System contractor — McAlvin goes on, … “During the proposal stage of this design/build project, a preliminary estimate was created based on a single sketch of a floor plan. With a multiple array of projects in McAlvain’s past experience, we were able to successfully and confidently present a realistic budget with little more than a concept. With the design phase at its end, we have proven this original budget was realistic and have been able to add scope and value engineering opportunities.”
The project has garnered some local media. The awesome custom Nucor Building System frame facility has been featured by Boise Weekly and discuss SkyScraper Forum.
“We’re excited to have a new, state-of-the-art facility in Boise to help us keep our fleet in top condition,” said Bill Dykes, SkyWest’s Vice President of Maintenance.
Have you ever looked for a Northern Indiana Metal Building Contractor in the Michiana region?
If so, odds are you know all the applications of these pre-engineered steel structures.
There are steel buildings for agricultural farms, industrial garages, large churches, multi-unit living complexes, warehouses, and much more.
The fact is, due to the open landscape of Northern Indiana strong winds from the west and lake effect snow from the Great Lakes present a challenge to traditional commercial buildings owners.
Metal Building versus Traditional Commercial Structures
Lower Insurance Payments
First, there are the higher insurance replacement costs.
Due to a commercial steel buildings exponential lower cost versus traditional buildings, small business owner can typically expect to pay at least 20% less on full replacement premiums.
Resistance To Fire
Another reason, to choose a pre-engineered steel building is due to a natural safety feature — the fire resistance of steel.
According to one metal building kit manufacturer, …
steel building are non-combustible, [where as] … wood framing simply acts as handy fuel for the fire, but steel framing does not feed a fire.
Research conducted by the National Fire Protection Association, and released in November of 2015 indicates “there were 1,298,000 fires reported in the United States. These fires caused 3,275 civilian deaths, 15,775 civilian injuries, and $11.6 billion in property damage.
And, if you want to add-on … “please do” would be the response.
A few days ago, in relation to the topic of versatility a steel building manufacturer wrote:
Complementary structural components can easily be accommodated during construction while new installations can be introduced any time should there be any changes in loading requirements or building use.
What are metal building construction systems (MBCS)?
Also known as pre-engineered metal buildings, MBCS are proprietary types of metal structures.
These metal buildings are designed and manufactured by MBCS companies like:
Nucor Building Systems
Within the South Bend Region, Nucor metal buildings systems are quite popular, and 95% of them are erected by Kemp Construction.
In addition, MBCS account for over 65% of of low-rise nonresidential buildings across the lower 48 US states.
However, popularity does not signify, ease of construction.
Construction of a pre-engineered steel buildings is similar to the construction of other buildings in that everything starts with a strong foundation.
MBCS companies and their metal building contractors are commonly asked …
Q: Is the foundation part of the metal building package?
The short answer is — NO.
However, Whirlwind Steel provides a more detailed explanation on their website.
A: The foundation is designed for each metal building and laid prior to erecting the building. The foundation design for a metal building is typically performed by an engineer for a specific project and not by the building manufacturer or contractor.
Of course, prior to having the steel building foundation poured, the Michiana territory land must be professionally surveyed.
This serves two purposes:
It ensures the building site is level and ready to be constructed upon.
It give the metal building contractor and cement pouring engineer the exact boundaries of the plot.
For more details related to concrete pour check-outBuildingGuide.com, they provide very specific guidelines and can even help you get a quote in places outside the South Bend region.
We might also want to check-out Youtuber “God’s Country” has they demonstrate the concrete slab pouring process on an 80′ X 100′ area.
Absolute Steel, mentioned early, has had many years in the MBCS industry.
For concrete slab mounting, they recommend the following:
… anchor your structure to a concrete foundation. This is a stronger and more stable method of anchoring plus once you have a level concrete surface to work with, installation is easier.
Armstrong Steel, also mentioned earlier is another veteran in the MBSC sector.
In addition, local building authorities will have specific frost line mandates and enforced requirements within the Michiana area.
In addition, to these challenges faced by South Bend metal building construction companies, the various land designations; i.e. agricultural, commercial manufacturing, multi-unit housing, commercial non-profit [ church], municipal, and others, further complicate the types, style, and manner of pre-engineered building construction.
To further complicate matters, until recently the design procedures have not been well understood, because they are not specified in the federal, state, city, or even industry building codes and technical design guides.
Since, every building is only as good as its foundation, the foundation designs produced by different engineers for the same metal building structure could range from those that cost a trivial amount to those that are quite expensive to construct.
Fortunately, as an authorized Nucor Building Systems commercial contractor, Kemp Construction and our hand selected certified building partners have benefited from guidance provided within the Nucor Building System Specification Guide, as well as, its cement division.
See a comprehensive list of Nucor Build System concrete product manufacturers below:
At Kemp Construction Company our custom metal building design and solutions are all centered around the benefits of working with Nucor Building Systems.
Nucor Building Systems has been a metal building construction industry leader for the design and manufacture of custom-engineered metal building systems for well over 25 years.
Their avid focus on customer service, price, and premium quality materials has allowed Nucor Building Systems to grow and expand within all of North America.
While most of this discuss is applicable to most metal building systems, please note that since Kemp Construction has such a strong relationship with Nucor Building Systems some information is not accurate for other brand — even if they are owned by NBS, or, one of its subsidiaries.
The components of a Nucor steel metal building system
Pre-engineered buildings are factory-built buildings of steel that are shipped to site and bolted using high-strength bolts and nuts at critical joints.
Great speed is achieved because while the foundations and floor slab are being constructed, the structural system consisting of the beams and columns are being fabricated in the factory by Nucor Building Systems.
The foundations for pre-engineered metal buildings are made with conventional concrete systems. Most commonly these concrete systems are of the open foundation variety.
The concrete as we discussed on another blog post is critical to the safety of the metal building, briefly here is why…
The impact of wind on by metal building structures
Nucor Building Systems are usually quite large in stature, and as a result, similar to other large building structures — they tend to attract a fair amount of wind force from different directions.
Roof damage can be caused by high wind air pressure below the roofing assembly when the air pressure is greater than the air pressure above the building’s roof.
As this force of wind passes over the roof of your metal building, the pressure directly above the surface of the roof decreases.
Simultaneously, internal air pressure is increased due to air infiltration, which typically comes from planned openings like garage doors, windows, or manufacturing exhaust vents.
Of course, Nucor Buildings Systems are adaptable to a number of energy-efficient insulation systems from basic fiberglass to rigid board and insulated metal panels, even prismatic skylights can help maximize energy savings by significantly reducing building operating costs.
Nonetheless, this powerful cause and effect of wind creates a net upwards phenomena known as “uplift”.
Since Nucor Building System are active members of the MBMA Energy Committee and the U.S. Green Buildings Council, and help to set the bar concerning energy efficient buildings and green construction practices, their metal building systems have a published rate of 89% or higher recycled content which leads to structure weight of as little as 50 kg per square meter.
In other words, Nucor Building Systems steel building can be an exceptional choice for your LEED® projects, as the building are of high-quality weather-proof design and light-weight. Please, note the foundation(s) and floor slab is not included in the estimate.
Despite top notch grade Nucor Building Systems material, and excellence of Kemp Construction design and installation the need to combat uplift was of a concern to the Nucor Building Systems engineers.
The solutions to uplift on Nucor Building Systems
Every Nucor metal building has at its foundations custom designed with joint assembly points for the purpose of firmly anchoring the entire structures to the ground with bolts, preventing them from being blown away by the uplift effect of wind.
Nucor Building Systems do not stop there, they also exceed the standards set by FM Approvals.
FM Approvals is a nationally recognized testing laboratory that tests and certifies building materials, fire protection and electrical equipment that can help prevent or reduce property damage.
Those products and services that meet FM Approvals’ rigid testing criteria become FM approved and bear the “FM” diamond certification mark.
Setting a firm foundation
The flooring of a typical metal industrial or steel storage building is usually a thick (about 6″ to 8″ ) concrete grade slab that rests directly on the prepared earth beneath it.
The concrete can be topped with a thin, abrasion resistant smooth coating called an epoxy floor or polyurethane floor if desired.
This style of construction is ideally suited to industrial buildings and warehouses; it is cost-effective, very fast to erect, and can also be dismantled and moved to another site – more on that later.
The Nucor Steel Building has these same features with the added benefit of its own supplier of welded wire reinforcement, Harris Supply.
As a result Nucor concrete foundations and slabs are reinforce with a full range of industry leading and advanced innovations in epoxy coated WWR where rebar and/or steel remesh products are needed.
Dried into the concrete foundation and slabs are 1.25″ industrial grade Nucor steel fasteners anchor bolt with a projection of 3” above the bottom of the baseplate, see image above for details.
Grout thickness needs to be added to the projection where grout is used in ensure a precise fit and to hide the column base and anchoring bolts [see image below].
Nucor Building Systems require that the Nucor Anchor Bolt Setting Plan be used in lieu of the Architect’s Anchor Bolt Setting plan at all times.
The Metal Building Structure and Secure Design
The columns and beams of Nucor Building Systems consist of custom-fabricated I-beam sections that have an end plate with precision cut holes for bolting at both ends.
These I-section members are constructed by cutting Nucor steel plates of the desired thickness, and welding them together to assure joint integrity, and eliminate cracks.
Welding the section is another design feature to combat uplift as discussed earlier.
The cutting and welding of the I-beam sections is manufactured via cutting edge automation. These industrial robots offer a high degree of speed and accuracy; the robots of overseen by human operators who will simply feed a CAD drawing of the beams into the machines, and then monitor the robots as they handle the task.
Once the foundations and floor are dried solid and pass inspection, the steel columns are shipped to Kemp Construction at the build site.
Upon arrival the painted steel sections, we utilize cranes to lift the sections into proper place and begin what we consider the most critical part of metal building construction …
… the fastening of I-beam section members to each other, and securing them to the concrete foundation and protruding Nucor structural fastener anchor stud bolts.
In large buildings, construction can start with two cranes working inwards from both ends; as they come together, one crane is removed and the other finishes the job.
The Role of Nucor Fasteners In Metal Building Safety
The proper tensioning, or tightening, of high strength structural bolts is essential at the slip-critical (or slip-resistant) joints of metal frames, and is the secret sauce to achieve engineered strength of a Nucor Building System.
If engineered strength is not attained, resistance to wind, snow, seismic loads, and other factors may cause the building frame to distort or worse fail.
Unfortunately, even though Nucor Building Systems has its own supplier of 6 different types of industrial fasteners as seen listed below, anchor bolts and nuts are not supplied by Nucor as part of the building order.
A critical bolt failure can make all the difference between a high performance system and a broken high priced device. It takes just a single compromised bolt to cause untold damage to both the system and the very facility the system is located.
That said, insufficiently tightened fasteners may result in loosening of nuts on stud over time, and ultimately ceasing to contribute to the metal building frame stability.
Since each piece of the Nucor Building system is very much alike they are able to be fastened with a consist type and size of fastener at various points, and thus only 6 types of fasteners are required.
Fastening materials included for contractors
Nucor supplies all it approved builder, like Kemp Construction (3) sets of 11” X 17” anchor bolt setting plans on all building orders.
Usually, each connection calls for six to twenty bolts to be installed. Bolts are to be tightened to exactly the right amount of torque using various wrenches.
All anchor bolts are ASTM F1554 Grade 36 unless noted otherwise. Nucor sizes the anchor bolt for shear and tension at the column base.
However, it is important to know that all aspects of the foundation design including anchor bolt embedment length and development to the concrete is not by Nucor.
Instead, the responsible architect or engineer for a specific project must see to it that the concrete is done by a professional who is qualified for this type of work.
Now remember earlier we mentioned that the I-beam section members had open end plates for bolting them into the concrete?
While most of the other sections of a Nucor Building System can be fastened with manual spud wrench, the foundation structure should be fastened at minimum with a high quality Milwaukee or Ingersoll Rand type of impact wrench.
However, for maximize benefit and precision a controlled tightening device like a TTP 1 Pneumatic TorcGun which ranges from hex size 1″ to 2 3/8″ is highly recommended by Kemp Construction especially on 1 1/2 inch to 2 1/2 inch bolt hex.
Approved Procedures for Tensioning Bolts
There are two generally accepted methods for tensioning high strength bolts on metal framed buildings. These are:
Bolt is tightened as snug as possible with a 14″-16″ spud wrench similar to the ones manufactured by Klein Tools.
A mark is made on a point of the nut and on the frame at the same point. Using a 4′-6′ cheater bar or using an impact wrench, the nut is tightened two points past the mark on the frame.
Calibrated wrench method.
The nut and bolt is paired tightened using a calibrated wrench, (not a common torque wrench), and is tightened to the manufacturer’s specifications.
Other methods approved by the manufacturer or project engineer may be used with prior approval of the Building Official.
After final tightening, we recommend the fastener be distinctively marked with paint or light colored indelible marker, to indicate the nut and bolt has been fully torque within specification.
Anchoring The Safety of Metal Building
As we have shown you, pre-engineered metal buildings require a firm foundation, welded integrity of seams, and precision bolting of its components to each other and the concrete base and slab.
Doing so prevents “uplift” created by wind force to damage the roof and wall sections.
The cement mix and steel rebar play an essential part in the laying on the concrete foundation and slabs.
Spud wrenches and impact wrenches are used to fasten most bolts, however, the 3″ anchor bolt extending from the base of the concrete are recommended to be tightened with a calibrated pneumatic torque wrench to achieve maximum accuracy.
Should you have any questions, comments, or thoughts regarding this post; High Strength Bolting Keeps Nucor Building Systems Secure, or any other matter please contact Kemp Construction, for a Nucor Building System quote call us at (574) 773-4994 .
A metal building by Nucor can satisfy your demands for both today and tomorrow. Many industrial buildings today house manufacturing processes that require the lifting or moving of heavy and large objects, and often incorporate a variety of material handling systems. Custom designed for your requirements yet economical – call Kemp Construction today for next industrial building.
We keep up on trends within construction and our community. This leads to being an expert who not only knows a craft, but, understands the purpose, challenges, and best fit solutions needed to satisfy clients, governance, and community.
Kemp Construction is one of the few Nucor approved commercial steel building constructors within the region.
As your custom steel building manufacturer, Nucor produces a wide array of structural systems, which means your Nucor building can be designed to virtually any desired dimension to achieve your optimal design solution. Every Nucor metal building will be custom designed to meet your requirements.
NBS has made a promise to be environmentally conscious to its employees as well as the rural communities where our plant-s are located. As a member of USGBC and a published rate of 89%+ recycled content, you have the ability to earn LEED points with your Nucor Building.
Kemp Contractors is a second generation family-owned business that was founded in 1984. Early projects consisted of residential and remodeling work along with small concrete projects. In 1990 the company expanded to commercial and industrial structures, including some concrete work. Kemp Contractors has the experience, expertise, and equipment needed to design and build 100,000 sq. ft. structures.