Thief River Falls Regional Airport Cargo Hangar

Challenge

Thief River Falls and Northwest Minnesota are experiencing significant economic growth, driven by major businesses like Digi-Key, Polaris, and Sanford Health. This boom has created a surge in demand for air cargo services at Thief River Falls Regional Airport (TVF). Major carriers such as FedEx, UPS, and DHL have upgraded to larger aircraft, like the CRJ200, to meet the region's growing needs. Digi-Key alone accounts for approximately 700,000 air-shipped packages annually, while other businesses depend on overnight cargo for critical operations.

However, the airport's existing multi-purpose hangar and apron were not equipped to handle the larger aircraft or increased cargo volumes, resulting in operational inefficiencies, particularly during harsh winter conditions. The current hangar could not accommodate two CRJ200 aircraft simultaneously, requiring outdoor storage and loading, which compromised reliability in extreme cold. The cargo area also became congested with carriers, trucks, and support equipment, creating safety and efficiency challenges.

Solution

To meet the growing demand for air cargo, TVF collaborated with SEH to design a state-of-the-art facility. The project included a 27,000 sq. ft. hangar with two bays, 2,000 sq. ft. of office space, a parking area, an aircraft apron, an access road, and utility connections. The hangar was designed to accommodate two CRJ200 aircraft for cargo loading, with provisions for a future third bay.

The project also addressed comprehensive electrical needs, incorporating robust 480V and 120/240V power distribution systems, lighting, communication and data networks, and an onsite backup generator. A major milestone was the completion of the aircraft parking apron in 2022, which delivered immediate operational benefits for all airport traffic.

Maximizing Funding and Grants

Funding played a critical role in developing the air cargo hangar at TVF, particularly during the challenging economic climate of 2020. Despite rising labor and material costs, the airport successfully planned, programmed, and secured grants to fund two key design and construction projects.

The TVF Airport Authority's deep understanding of funding programs, state and federal participation levels, and additional funding requirements proved essential. By leveraging multiple rounds of bonding and federal grants, the financial burden on local resources was minimized.

Through the Congressionally Directed Spending Program, federal contributions totaled $7.5 million, secured with support from US senators and the TVF Airport Authority. Additionally, the CARES Act allowed the federal share of the apron project to cover 100% of federally eligible pavement costs.

The State of Minnesota contributed $8.5 million through two rounds of bonding for the cargo hangar, supported by MnDOT. The state also covered 70% of federally ineligible portions of the apron.

Coordinating Design for Regulatory Success

The design phase required addressing challenges such as wetland permitting, stormwater management, and erosion control while ensuring compatibility with future expansion plans. Close coordination with state and federal agencies, including MnDOT's Office of Aeronautics and the Federal Aviation Administration (FAA), was critical to the transition from conceptual planning to detailed construction documents. The team maintained strict compliance with the National Environmental Policy Act (NEPA) throughout the process.

Fulfilling Sustainability Commitments

The project adheres to Minnesota B3 Guidelines for New Buildings and Major Renovations, a requirement for Minnesota Capital Bond Grant funding. These guidelines mandate that new buildings meet sustainability goals for site, water, energy, indoor environment, materials, and waste.

To achieve B3 compliance, SEH integrated design alternatives and modeling beyond typical project requirements. Close collaboration with TVF and multiple agencies ensured adherence to the B3 tracking tool while maintaining the project’s schedule, budget, and stakeholder goals.

Bringing the Vision to Life

The completed building marks a significant milestone in supporting the region's economic growth. This state-of-the-art facility enhances the airport's capacity to meet the demands of larger aircraft and growing cargo volumes, ensuring safe, efficient, and reliable operations year-round. Its modern design now enables carriers to better serve regional businesses, reinforcing TVF's role as a critical hub for Northwest Minnesota's economy.