CAE Savannah Flight Training Center

Despite record-high lead times for building materials and mechanical, electrical, and plumbing (MEP) equipment, the project team secured an on-time delivery through consistent communication and proactive collaboration on this design-build project.

Due to the advanced technical nature of this project, highly specialized equipment was needed to deliver the complex MEP systems. Without proactive planning and early procurement under current market conditions, the project schedule could have been significantly delayed. Understanding the sophistication of this MEP package, the project team worked together with stakeholders to identify and release key trade packages early, including those for the switch gear components and an energy efficient chiller.

As the flight simulators emanate high levels of heat, the team installed both a conventional standard chiller and an oil-free, magnetic bearing centrifugal chiller – the latter of which reduces maintenance costs and increases sustainability in the long term, resulting in significant savings for CAE. Additionally, design plans called for six remote terminal units (RTUs), 35-to-40 variable air volume (VAV) systems, and fan cool units, as well as a breathable air system for the simulator cockpits which needed surgical-grade copper piping and tubing.

The facility also included a server room with raised access flooring to house all power and data infrastructure for the four FFS. Included in the room is an uninterruptible power supply (UPS) in case of electrical outages and four computer room air conditioning (CRAC) units to keep all data center and simulator equipment cool.

With all of these complexities, Choate’s in-house MEP Specialist was integral to ensuring seamless construction and implementation.

The four FFS in this facility offer the same range of motion as a real airplane cockpit, requiring a clearance height of 30 feet or more. To build this space alongside a world-class office building adorned in high-end finishes, the design team did something rarely seen in construction: joining a pre-engineered metal building with a conventional structural steel building. The pre-engineered metal building offered the height and clear space needed to operate the simulators, while the structural steel building offered the high-end aesthetic desired by the client.

To execute this design plan, the project team worked with the engineers for both buildings to align structural systems, coordinate the installation of MEP systems, and account for height differentials. In addition to their meticulous pre-planning, the project team worked with highly experienced trade partners for onsite installation.