Airport design

→ Airport design

The design of the modular airport was a challenge. Airport buildings are characterized by large open spaces with high ceilings and without the columns typical of modular construction. Therefore, we had to take a different approach to the design itself. A design was elaborated where the modules are arranged in rows and serve as columns that form the basic structure of the airport, upon which the partial roof structure is placed. This created the open airy spaces of the high clearance halls. To test the system in practice, we manufactured and assembled a prototype in Vizovice. We tested it, verified the functionality and safety of the whole system to make sure that it met all requirements and standards. After successful prototyping, we were able to start serial production of all 142 modules that make up Saint-Louis Airport.

→ Technical specification

The steel-framed structure of the modules is made of bent galvanized profiles based on static calculations provided by a certified company in accordance with Eurocodes. The dimensions of the supporting frames are L6050 or 3025 × W2430 × H3000 mm. The load-bearing structures of the glazed facades and the main hall of the terminal are also made of steel – the roof cladding is made of sandwich thermal and waterproofing panels. The building is designed to withstand a maximum wind intensity of 41 m/s. The building has a secondary cladding with sandwich thermal insulation panels.

Window openings are filled with triple glazed aluminum profiles with a high solar filter to minimize heat transfer into the building and improve thermal comfort inside the building.

→ Technologies used

In general, the aim was to make the airport as simple as possible so that the operation would be as easy as possible taking into account local staffing and conditions. The outdoor ventilation and air-conditioning units are installed in modules on the roofs of the buildings. The units were assembled at the manufacturing facility – entire modules were then lifted onto the roof and only the connection of the units was carried out on site.

Due to insufficient water sources on site, it was not possible to use conventional extinguishing sprinklers. Therefore, a mist sprinkler system was installed, which uses a much smaller amount of water.

→ Terminal building

The passenger terminal is the main building in the planned Saint-Louis airport complex. The building is designed for international commercial air traffic. The expected LoS for the Saint-Louis terminal, according to the international IATA and DGAC classification, is equivalent to Level E. The airport has a handling range designed for a peak daily capacity of 2 Boeing 737-300 aircrafts with 154 departing and 154 arriving passengers.

→ Technical highlights:

The roof panels were already coated with TPO foil during the production, only the joints were made on site. Full-scale bonding on site was unrealistic due to dust and strong winds. Due to the location near the sea, the strong winds, and the subsoil, we had to design for high static loads. The secondary façade is attached to the frame without the use of a grid; we had to modify the profiles for this purpose in the factory. The steel in the halls is fire protected for 30 minutes. The exposed profiles of the steel structure and the roof are structurally designed for this fire resistance. The module frames are protected by SDK cladding. The cladding was also used for cable routing throughout the structure. No vapour barrier is used in the buildings – this is due to the climatic conditions.

Facilities and services related to the checking of passengers’ boarding cards on departure

Passport control on departure and lounge

VIP lounge for passengers on departure

Departure gate lounge

Security scanning of passengers’ hand baggage on departure, waiting area

Gate for checking passengers before boarding the aircraft on departure

Baggage security check, overweight baggage check-in

Check-in counters and lounge

Hall for the public and for passengers on arrival

Customs control for passengers on arrival

Post-arrival passenger control equipment

Airport design

Baggage reclaim area

Automatic belt

Passport control on arrival and lounge

Post-arrival passenger gates

The terminal and hangar buildings were designed by the Borci s.r.o. architectural studio, architects Sikora and Borecký. The production documentation was prepared in cooperation with KOMA MODULAR s.r.o. and other subcontractors. The project was conceived in 2021 and implemented in 2022.

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