Kansas City Aviation Overhaul Base - Sika Sarnafil Project of the Year Application Video

Join Account Manager Linn Fredlund as he discusses the Kansas City Aviation Overhaul Base. The base, an iconic part of the KCI silhouette, has been in dire need of a purpose and work for decades. The chance to reinvigorate such an iconic structure is a true honor, one that we at JR & Co., Inc. did not take lightly.
Designed by world-renowned architect Eero Saarinen, the base was built in the 1950s for Trans World Airways (TWA), known for its transcontinental service and its principal stockholder, Howard Hughes. The buildings, a million square feet in total, were designed to service TWA's entire fleet. Saarinen's career is notable due to projects like JFK International Airport and the Gateway Arch in St Louis, Missouri. His use of thin-set concrete and inspired designs made him a perfect fit for the base. This structure was likely the first to utilize cables to support the roof rather than a more traditional method. The design includes a poured in place concrete deck, approximately 4" thick, which the steel cables run through in sleeves and are collected at the structure's base. Structurally, the base is stunning, with one major swale that has a compound slope to roof drains and then intersects with an inverted and compound sloped area above the airplane entrances.
In its prime, thousands of mechanics worked in this structure, making it Kansas City's largest employer in the 1960's and 1970's. 6,000 employees worked there daily, repairing TWA's fleet. After the deregulation of the airline industry, TWA became defunct. And, after American Airlines absorbed TWA and moved operations out of Kansas City, the hangar sat in a state of disrepair, awaiting the day it could once again become a booming center for maintenance.
In 2010, Kansas City's Aviation Department took possession of the structure. However, as the search for tenants continued, the structure received little upkeep, creating a variety of issues. These included a significant number of leaks and vegetative growth due to water absorption and atmospheric soiling. This latter issue led to the growth of trees, grass, and moss growing out of the 1.5-2" thick polyurea foam (PUF) roof. In recent years, a new firm took up residency in the hangar, allowing the building to receive the TLC it deserved.
Through a collaboration of the design firms of Walter P. Moore (WPM) and Wellner Architects, the initial project started on an attached structure, a collection of 139 inverted, poured in place concrete pods that also had a polyurea foam (PUF) roof. After a series of change orders, the two twin Parabolic Structures were next to be reroofed. As shown in the photographs, there are some areas where the pitch is 18/12. As the planning began, it was clear heat loss was not a major consideration, as the structures have doors large enough to pull in several Boeing’s. That said, the decision was made to adhere to the 80-mill fleece-backed Sarnafil S 327 directly to the concrete. Longtime Sika Sarnafil field Inspector Phil Cook was instrumental in advising the lead Design member from WPM, Laurie Woods, on the advantages of using low rise foam adhesive to adhere the membrane to the concrete. During the project, the deck's cores were cut and analyzed for their integrity, and all came back +/- 4,000PSI. Kyle Dominisse of WPM was their lead on the Structural analysis team and was the driving force behind the mounting of vectors placed on the roof so that precise movement of the structure could be recorded.
Substantial Completion was June 4th, 2020, and at that time, we all felt a sense of pride knowing that we had been able to extend the life of a one of a kind structure. Many thanks to the hardworking JR & Co., Inc. employees who worked tirelessly on this demanding and unique project. Special thanks go to Abraham and Isaiah Nichols, the Co-Foremen of this project.
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JR & Co. is an energetic, optimistic, and family-oriented construction company established in 1986 and headquartered in Kansas City, MO. While our primary focus is roofing, we offer a wide variety of services, including sheet metal, tenant finish, federal contracting, solar installation, disaster relief, rooftop maintenance, and roof restoration. We are determined to provide our customers with all their building envelope needs, including consultation, construction, and project oversight.
Recognized by the leading roofing and construction industry manufacturers for outstanding workmanship and customer service, as well as an A+ rating from the BBB, JR & Co. is a superior choice. JR & Co.’s value for employees, customers, and the community is what sets us apart in the roofing and construction industry.
Visit us online at www.jrcousa.com to schedule your free consultation, or call at 816-587-6148.