The Steven F. Udvar-Hazy Center in Virginia

National Air and Space Museum Steven F. Udvar-Hazy Center

Location Chantilly, VA

Category Cultural

Focus Area FacadesRoofsWaterproofing Design

Building Enclosure Rehabilitation and Water Infiltration Remediation

With more than 60,000 artifacts in their collection, the Smithsonian Institution’s National Air and Space Museum on the National Mall in Washington, DC could display but a tiny fraction of their holdings to the public, until a generous gift from Steven F. Udvar-Hazy funded the construction of a 760,000-square-foot companion facility at Dulles International Airport in Chantilly, Virginia. Designed by Hellmuth, Obata, and Kassabaum, architects of the National Air and Space Museum, Udvar-Hazy Center comprises three hangars, archive collections, a conservation laboratory, classrooms, an IMAX theater, and an observation tower overlooking the adjacent airport. The expansive facility, designed to evoke airport terminals, is arresting in its sweeping lines and homage to the history and possibilities of air travel. Unfortunately, since its initial construction in 2003, the Udvar-Hazy Center was dogged by persistent water and air infiltration issues.

Hoffmann joined URS and Hartman-Cox Architects as the building enclosure consultant for an ambitious rehabilitation project to resolve leaks at the sprawling aviation center. Beginning with a comprehensive evaluation into the underlying causes of water and air infiltration, our design professionals undertook a programmatic study to develop recommendations for cost-effective and appropriate remedial action.

In a multi-year construction project completed while the museum remained continuously open to visitors, Hoffmann oversaw the meticulous rehabilitation of the entire enclosure, from the ground up. The complex geometry of the roof areas, along with complicated intersections where various building envelope systems meet, demanded painstaking attention to see that detailing provided resilient protection from the elements. To allow for continuous use during construction, Hoffmann specified partial replacement of the barrel vault roof of the main aviation hangar at targeted areas, with a roof overlay providing waterproofing protection throughout. The inverted roof assembly at the loading dock terrace was fully replaced. At the theater, restaurant, “fuselage” area, and non-hangar exhibit spaces, parapet wall waterproofing and parapet-to-hangar transitions were reconstructed to resolve leaks.

View Slideshow of the National Air and Space Museum Steven F. Udvar-Hazy Center case study

The Smithsonian Institution's Steven F. Udvar-Hazy Center is a 760,000-square-foot companion facility to the National Air and Space Museum at Dulles International Airport in Chantilly, Virginia.

The complex geometry of the roof areas, along with complicated intersections where various building envelope systems meet, demanded painstaking attention to detailing.

Points where different assemblies intersect were meticulously illustrated in drawings that detailed construction sequencing and waterproofing.

Waterproofing at roof/wall intersections and other terminations resolved persistent leaks.

Hangar roofs presented challenges, particularly in the continuously occupied museum.

A historical aircraft suspended from the ceiling in the hangar of the Udvar-Hazy Center

The Smithsonian's Udvar-Hazy Center displays historic aircraft in the hangar-like space, which had been experiencing water infiltration issues.

The facades at Udvar-Hazy are composed of varied materials and assemblies, which leads to especially complicated transitions. Where different assemblies intersect, Hoffmann’s documents provided minutely detailed axonometric drawings to illustrate construction sequencing and waterproofing details. Metal panel wall assemblies, for instance, required partial removal and reinstallation to accommodate waterproofing transitioning. For ceramic tile facades, Hoffmann specified targeted sealant replacement, while glazed window wall and translucent wall system restoration involved comprehensive resealing, gasket replacement, and new flashings. Subgrade waterproofing was installed along the east building face, and a new snow guard system addressed issues with cascading snow impacting lower roof areas.

During construction, and again after installation, Hoffmann oversaw rigorous field testing of materials and assemblies to confirm the success of the detailing. Air and water infiltration resistance and other performance testing verified that the design met real-world conditions and provided the requisite enclosure integrity.

As the building enclosure consultant, Hoffmann collaborated with the project team and with stakeholders at the Smithsonian Institution to deliver resilient, cost-effective, and durable weather protection for the visually arresting aircraft museum. Addressing the complex design challenges while maintaining continuous access to the collections throughout the multi-year construction project demanded coordination among tradespeople, contractors, testing laboratories, designers, and museum facility personnel, as well as thorough and exacting design documents. The result is a building enclosure that the Smithsonian can depend on to protect its historic and unparalleled collection of aviation and space artifacts for generations to come.

In a multi-year construction project completed while the museum remained continuously open to visitors, Hoffmann oversaw the meticulous rehabilitation of the entire enclosure, from the ground up.

View out the window at Udvar-Hazy Center

The observation tower overlooks the hangar, with Dulles Airport beyond.

Entrance to Udvar-Hazy Center, with observation tower in background

Glazed window wall and translucent wall assemblies underwent resealing, gasket replacement, and new flashing installation.

The varied assemblies of the facades make for complex intersections.