Asia Digital Engineering MRO

Hangar and Maintenance, Repair and Overhaul (MRO) at Jalan KLIA S7, KLIA.

Project Overview and Design Intents

The 20-acre site, strategically positioned between Jalan KLIA S7 and the KLIA runway, has been designated by the client for the development of a state-of-the-art Hangar and Maintenance, Repair, and Overhaul (MRO) facility. This facility is engineered to accommodate up to 14 nos. A321 aircraft simultaneously or, alternatively, 2 nos. A330neo aircraft and 8 nos. A321 aircraft simultaneously.

The following client requirements and design intents have significantly influenced the consultants' architectural approach, construction methodology, and material selection for this project:

1. Aviation Safety Compliance: Ensuring that the operational safety of incoming, outgoing, and stationary aircraft remains uncompromised, strictly adhering to the Civil Aviation Authority of Malaysia (CAAM) regulations and compliance standards.

2. Precision Construction Techniques: Implementing precise construction methodologies to maximize the spatial efficiency of the site, allowing the intended number of aircraft to be accommodated within the limited footprint, particularly given the L-shaped configuration of the hangar.

3. Time-Sensitive Construction: Adopting accelerated construction timelines due to the site’s proximity to sensitive and restricted zones (airside/landside), necessitating careful coordination to minimize disruptions to airport operations.

4. Column-Free Spanning: Designing expansive, column-free spans to facilitate unobstructed manoeuvrability of aircraft within the hangar, addressing the need for large, open spaces essential for aviation operations.

5. Architectural Representation: Crafting a façade that reflects the client’s esteemed position in the aviation industry, with a design that embodies both functionality and the client’s corporate identity.

Achieving the Design Intent

In pursuit of the design intent, and with meticulous consideration to ensure that the outlined objectives remain uncompromised, the materials for the facades and roofs were meticulously selected. The “Swisma-Sanko Speed Deck” for the facades and “Swisma-Sanko Seam Lock” for the roof were chosen, covering approximately 50,500m² of surface area.

The diverse range of Swisma-Sanko cladding options was instrumental in achieving the intended façade design, which emphasizes the sleek and modern aesthetic of the overall structure. Simultaneously, the façade and roofing materials were carefully selected to minimize glare, ensuring the safety of nearby aircraft in flight.

The integration of Swisma-Sanko with the predominantly steel structural framework not only complements the building’s architecture but also accentuates the quality and refinement of the steel structure’s detailing and finishes, internally and externally. This synergy between the cladding and structural elements underscores the sophistication of the construction.

The installation methodology adopted for the facade and roof materials has significantly streamlined the process, allowing the builder to meet the project’s tight timelines effectively.

Moreover, the innovative use of these facade and roofing materials has enabled the project to secure a Silver category certification under the Green RE. The carefully calculated thickness and composition of the materials ensured that the U-value and OTTV (Overall Thermal Transfer Value) targets were not only met but exceeded, contributing to the building’s energy efficiency.

The project has been distinguished by the Malaysia Book of Records for its remarkable achievements in the following categories:

1. Longest Single Span Pre-Engineered Building (PEB) System Rafter – 153 meters

2. Longest Locally Designed Single Span Truss Frame System – 183 meters

3. Longest Vertical Hangar Door (Megadoor) – 143 meters

These milestones were made possible through meticulous material selection and precise engineering. The strategic choice of materials was crucial in ensuring the structural integrity and performance of these record-setting elements, highlighting the importance of alignment between design intent and material specification in achieving such extraordinary feats.