Location: Kansas City, MO
Square Footage: 215,000 sq. ft.
Scope:
At its peak, the Kansas City Aviation Overhaul Base was the beating heart of Kansas City’s workforce, employing 6,000 mechanics daily to service TWA’s fleet. Throughout the 1960s and 1970s, it stood as the city’s largest employer, playing a vital role in the airline industry. However, with the deregulation of airlines and TWA’s eventual absorption by American Airlines, operations ceased, and the once-thriving facility fell into decades of disrepair.
By 2010, Kansas City’s Aviation Department took ownership of the structure, but as the search for new tenants stretched on, maintenance was minimal. Over time, the facility suffered from widespread leaks and even vegetation growth, with trees, grass, and moss taking root in the 1.5–2” thick polyurea foam (PUF) roof. Finally, after years of waiting, a new tenant committed to revitalizing the base, allowing it to receive the long-overdue TLC it deserved.
The restoration effort was a collaboration between Walter P. Moore (WPM) and Wellner Architects, beginning with a connected structure of 103 inverted, poured-in-place concrete pods, also covered with a PUF roof. After a series of change orders, the project expanded to include the twin Parabolic Structures, with some sections featuring an extreme 18/12 pitch.
Heat loss was not a primary concern, given the structure’s massive aircraft doors, so the decision was made to adhere 80 mil fleece-backed Sarnafil S 327 directly to the concrete. Low-rise foam adhesive was selected to bond the membrane securely to the deck. Structural integrity was confirmed through core testing, with results showing a +/- 4,000 PSI rating. Vectors were mounted on the roof to monitor any structural movement.JR&CO was honored to help restore this iconic landmark, ensuring its legacy continues for generations to come. This exceptional project was recognized as Sika Sarnafil’s 2020 Project of the Year, highlighting its significance in the roofing and aviation industries.