1. < Back to Articles

    Balfour Beatty Construction Achieves Major Milestone at Marine Corps Air Station, Camp Pendleton

    August 20, 2015


    Watch video: Project team successfully erects two steel box trusses – weighing nearly 500,000 pounds each – at double hangar project. 

    Balfour Beatty Construction has successfully completed the erection of two 475,116-pound, 10-foot tall, 20-foot wide and 340-foot long steel truss sections at the MV-22 Double Hangar project located at Marine Corps Air Station (MCAS), Camp Pendleton. For perspective, the assembled length of each truss is approximately the size of a football field plus another 40 feet. The milestone marks the largest single steel erection at MCAS.
     
    The MCAS double hangar project will support two MV-22 Osprey squadrons. The scope includes two maintenance hangars that each accommodate four MV-22 Osprey, which are tiltrotor military aircraft. The facility will include state-of-the-art, specialty maintenance shops, administration offices and training/mission planning accommodations.
     
    The steel trusses were delivered to the project site in eight sections, each measuring 10-feet tall, 20-feet wide and 82 feet long. To help mitigate potential safety risks, the erection process involved bolting four 60-foot sections together while simultaneously installing additional bracing throughout the process. Once all the sections were bolted together, Azteca Steel and Bragg Crane used two cranes in unison to move each truss into position. To complete the two-day process, four iron workers worked in unison on man-lifts to install the bolts once the trusses were in place.
     
    Planning for the steel erection occurred over a three-month period with a primary focus on safety. “Our team worked closely with Aztec Steel, Bragg Crane and government representatives to ensure all risk was eliminated,” said Brian Cahill, president Balfour Beatty Construction’s Southwest Division. “This is an exciting milestone and a testament to the strength and ability of the entire team.”
     
    Luis Adrianzen, Marine Corps Air Station PWD Project Leader commended the team for successfully completing the task: “The trusses are vital in the continuation of the hangar construction. The project team remained diligent throughout the process to ensure that every individual involved was included in the planning process - from the manufacturing, to the deliveries and the erection process. All of the pre-planning paved the way for a successful and flawless product with zero safety issues. The event was impressive in size and magnitude, while the process went seamlessly, with little to no intrusion on the daily operations.”
     
    Designed by KMA Architecture, the project is scheduled for completion in December 2015.