Project Description

The UAS Shadow Hangar project at Fort Drum is a $21 million contractor led design-build project awarded to Structural Associates, Inc. (SAI) by the U.S. Army Corps of Engineers. The project involved the design and construction of a new operational campus and supporting facilities for Unmanned Aircraft System (UAS) Group 3 operations at Wheeler Sack Army Airfield, Fort Drum, New York.

SAI served as the prime contractor, providing full design-build delivery and managing a team of multi-disciplinary design consultants, specialty subcontractors under direct contract with SAI, and SAI’s self-performed workforce. The team coordinated closely to meet the stringent U.S. Army and USACE technical, safety, and operational requirements.

The Shadow Hangar complex expands an existing Army UAS facility. All construction activities, including work adjacent to active facilities and the existing UAS runway, were carefully phased and coordinated to maintain uninterrupted flight and operational activities throughout the project duration.

Overall site development encompassed approximately 22 acres. In response to the operational performance requirements in the RFP Statement of Work, SAI and its design team delivered a fully integrated campus that includes a 28,100 square-foot UAS Group 3 Hangar, Sanitary Sewage Lift Station Building, Organization Storage Building, Aviation Fuel Station Shed, Petroleum/Oil/Lubricant (POL) storage and used POL storage, Fire Protection Pump Building, and Bulk Fuel Station.

Supporting airfield and operational infrastructure included a hangar access apron; UAS runway asphalt paved taxiway and shoulders; a UAS asphalt paved launch area; and an extension of the existing UAS asphalt paved runway, including shoulders and overrun area.

Additional site improvements included perimeter security fencing with controlled vehicle gates, upgrades to the existing 0.25-mile gravel site access road to asphalt pavement, and construction of new organizational vehicle parking and privately owned vehicle (POV) parking areas to support the increased staffing requirements.

Utility infrastructure supporting the new facilities included electrical distribution and service, security lighting, telecommunications systems, fire protection and potable water systems, extension and upgrades to the force main sewer associated with the new lift station, an underground fire suppression foam containment tank, storm drainage systems, and site landscaping.

The 28,100 square-foot Hangar is the largest facility within the complex and includes a primary hangar bay with adjacent administrative offices, training areas and support spaces. Building systems include fire detection and alarm, wet pipe sprinkler and hangar bay foam fire suppression systems, an intrusion detection system (IDS), and an Energy Monitoring and Control System (EMCS) integrated into the installation-wide monitoring system.

In addition to facility design and construction, SAI provided comprehensive interior design services, including a Structural Interior Design (SID) and Furniture, Fixtures and Equipment (FF&E) design. Interior furnishings were fully coordinated with the building construction to support efficient installation and immediate operational readiness upon occupancy.

The successful completion of the UAS Shadow Hangar project demonstrates SAI’s ability to deliver complex, large-scale design-build aviation facilities within an active military airfield environment while maintaining mission continuity.