Building Technology, Size, and Location

The Aero Center FBO in Wilmington, NC, is a cutting-edge, 18,000 sq. ft. aviation facility that we at Coastal Steel Structures proudly contributed to. We supplied the pre-engineered metal building (PEMB) system, chosen for its exceptional strength, cost-efficiency, and ability to accommodate future expansions. Our role was to ensure that the facility met all necessary structural and environmental regulations while also achieving the sleek, modern design envisioned by the client.

Building Purpose Overview

We designed the Aero Center FBO to meet the diverse needs of both private and commercial aviation operators. Our goal was to create a facility that offers a full spectrum of essential services for the smooth operation of any aviation hub. The facility includes aircraft fueling, comprehensive maintenance services, and spacious hangar storage designed to accommodate various aircraft sizes and service requirements. We ensured these core operational services were seamlessly integrated into the facility’s infrastructure, making it a one-stop destination for aviation professionals and operators alike.

Project Challenges

Compliance and Design Aesthetics
The project needed to meet stringent aviation and environmental regulations without compromising its aesthetic appeal. Balancing these requirements was a key challenge during the design and construction phases.

Fluctuating Steel Prices
The global steel market experienced extreme volatility in 2021 due to the pandemic, leading to significant price increases. This created budget constraints and material procurement challenges.

Manufacturing Delays
Ongoing issues with the manufacturing of key building components led to unexpected delays, causing disruptions to the project schedule. These challenges made production timelines uncertain, requiring the team to adjust plans and manage expectations continuously.

Architects’ Inexperience with PEMB
The architectural team was relatively new to working with pre-engineered metal building systems, leading to design inefficiencies and revisions, which slowed the project’s progress.

General Contractor Change
At the end of the project, the original General Contractor was dismissed due to subpar performance and craftsmanship, requiring the project team to onboard a new GC.

Solutions Provided

Guidance for Design and Compliance
We played a pivotal role in ensuring the building met all regulatory standards while maintaining the desired aesthetic appeal. Our team worked closely with the architects and engineers to incorporate the latest PEMB technologies, ensuring compliance without sacrificing design quality. By offering flexible design options, we helped the project team navigate complex regulations while keeping the project visually appealing.

Cost Management and Material Procurement
Coastal Steel Structures took a proactive approach to mitigate the rising steel prices. By leveraging our extensive supplier network and industry relationships, we were able to lock in materials early and explore cost-effective alternatives, preventing further budget overruns. Our expertise in managing supply chain issues ensured the project stayed as close to budget as possible despite market fluctuations.

Support for Architects New to PEMB
Recognizing the architects’ inexperience with pre-engineered metal buildings, we at Coastal Steel Structures provided additional design support and technical expertise. Our team offered training and consultation to streamline the design process, minimizing delays and ensuring the architectural vision was seamlessly integrated with the PEMB system. This collaboration reduced inefficiencies and sped up design revisions, keeping the project on track..

Overcoming Manufacturing Delays
With Coastal Steel Structures’ extensive experience in handling construction delays, we introduced contingency planning and buffer timelines to accommodate potential setbacks from manufacturers. By maintaining open and transparent communication, regularly updating stakeholders, and working closely with the project team to adjust schedules as needed, we helped minimize the impact of these disruptions.

Seamless General Contractor Transition
When the original General Contractor was dismissed due to poor performance and craftsmanship, our experienced project management team swiftly transitioned to a new General Contractor that completed all final repairs. We coordinated with the new contractor, providing updated plans and ensuring all parties aligned on the revised timeline. Our hands-on management minimized disruptions and brought the project back on track.

Conclusions

What truly sets this project apart is how it showcases the extensive expertise of Coastal Steel Structures in managing intricate construction endeavors. From the outset, our strategic involvement was critical in addressing the unique challenges presented by this build. Our ability to balance stringent regulatory compliance with aesthetic objectives ensured that the facility met all aviation and environmental standards without compromising on the design vision.

Moreover, our proactive approach to mitigating challenges—such as fluctuating steel prices, unexpected manufacturing delays, and the sudden need to replace the general contractor—highlighted our deep understanding of the construction landscape. We consistently delivered practical, timely solutions to keep the project on track, even under difficult circumstances.

Our technical support was particularly vital when working with architects unfamiliar with pre-engineered metal building (PEMB) systems. We provided specialized training and guidance, which not only accelerated the design process but ensured that the final structure fully aligned with the architectural vision, marrying functionality and design seamlessly.

Final Results

As a result, the Aero Center FBO is not just another aviation facility—it stands as a model of efficient, modern design and construction. It provides long-term value to its operators through a facility designed for durability, future growth, and optimal operational efficiency. Coastal Steel Structures’ contribution was instrumental in ensuring the project was completed on time, within budget, and to the highest standards of quality.

Our involvement significantly enhanced the project’s success, leaving a lasting impact on the aviation community and positioning the Aero Center FBO as a premier facility in the industry. More importantly, we created a strong, long-lasting impression with the client, which has built a lasting relationship, ensuring trust and collaboration for future projects.

For more information, please contact Coastal Steel Structures.