Clearing the Way: Gerald R. Ford International Airport’s New Snow Removal Equipment Facility

In October 2024, Gerald R. Ford International Airport (GRR) unveiled its newly expanded Snow Removal Equipment (SRE) building, a state-of-the-art facility designed to ensure operational efficiency during Michigan’s harsh winters.

The $8.5 million project added more than 60,000 square feet to the existing structure, bringing the facility’s total size to over 117,500 square feet—equivalent to a football field in area and large enough to house more than 50 Olympic-sized swimming pools in volume.

The expansion was vital to meet the demands of a growing airport, with passenger numbers up 12% from 2023—a record-breaking year.

“This facility has been a long time coming,” said Michael Wouda, Airfield Maintenance Manager for the Gerald R. Ford International Airport Authority. “We were operating with equipment scattered across the airport and knew we needed a centralized, modern solution to stay ahead of operational demands.”

Identifying the Need and Tackling Challenges

Prior to the expansion, the airport’s previous 57,000-square-foot SRE facility was insufficient for its growing fleet of more than 45 specialized vehicles. “We had equipment stored across the property, some of it outside in harsh conditions,” Wouda explained. “That led to damage from exposure to sun, water, rodents, and even nesting birds. It wasn’t just inefficient; it was costly.”

The scattered setup also delayed response times during snow events, a critical issue for an airport located in one of the snowiest regions of the U.S. “It used to take us 15–20 minutes to deploy equipment,” Wouda added. “Now, with the new facility, we’re ready to roll in just five minutes.”

The decision to expand the SRE building came with challenges. One major obstacle was the need to relocate an outdated fuel farm to make room for the new structure.

“The fuel farm had been in operation for decades and wasn’t meeting modern standards,” said Jeff Berghage, Facility Design and Construction Project Manager for the Gerald R. Ford International Airport Authority. “Moving it was a logistical challenge, but it aligned with the airport’s long-term goals of modernization and sustainability.”

The project also required balancing construction with ongoing airport operations. Dave Lucas, Director of Construction at FCC Construction Inc., described the complexity of building on an active airfield.

“We had to maintain a clean and safe site while ensuring there were no disruptions to the airport’s daily activities. It required a high level of coordination between all stakeholders,” he said.

Collaborative Solutions and Innovation

The success of the SRE expansion stemmed from a collaborative approach involving multiple stakeholders, including FCC Construction, C&S Companies, and DLZ.

“We worked closely with the airport authority and maintenance team to ensure the facility met their needs,” said Amy Sonbuchner, Project Manager and Aviation Architect at C&S Companies. “Their input was invaluable in shaping the design and addressing operational challenges.”

The facility’s design reflects this collaboration, incorporating features that streamline operations and improve safety. Straight-through traffic patterns minimize maneuvering, reducing the risk of accidents, while specialized overhead doors — spanning nearly the area of two NBA basketball courts — facilitate quick ingress and egress.

“We spent a lot of time working with the maintenance team to optimize the layout,” said Ray Middleswarth, Project Engineer for C&S Companies and RFR for the project. “It wasn’t just about fitting the equipment — it was about ensuring the flow of operations was as seamless as possible.”

Durability was another key consideration. The building was constructed with materials specifically chosen to withstand Michigan’s harsh winters and support the longevity of high-value equipment.

“We needed a facility that could endure extreme weather while protecting the equipment inside,” Sonbuchner explained. “That meant investing in materials and construction methods designed for the long term.”

The facility also incorporates advanced training capabilities, a significant improvement for the Airfield Maintenance team. “We can now train on multiple pieces of equipment in a single session,” Wouda said. “In the past, we had to schedule training around the scattered locations of our equipment. Having everything in one place is a huge advantage.”

Setting a New Standard in Snow Operations

The expanded SRE building is more than just a storage space; it’s a hub for cutting-edge snow removal operations. The airport’s Airfield Maintenance team, a nationally recognized leader in snow removal, now has the resources to respond to winter storms with unparalleled efficiency.

“Our equipment is built specifically for the aviation industry and is far larger than anything used on public roads,” Wouda explained. “With everything housed in this new facility, we’ve dramatically improved our ability to maintain and deploy these specialized machines, which are critical for ensuring safe and efficient snow removal operations.”

During snow events, the team deploys in a conga line formation of seven or more trucks, clearing two miles of runway in under 30 minutes. This level of efficiency is critical for minimizing disruptions to flight schedules.

“The facility’s layout and design make these rapid responses possible,” Middleswarth said. “It’s a testament to the careful planning that went into every aspect of the project.”

The SRE building also accommodates future growth. “We designed this facility with evolving technology in mind,” Wouda explained. “Equipment has grown significantly in size over the past decade, and we expect that trend to continue. This building is ready for whatever comes next.”

Lessons Learned and Best Practices

The SRE expansion project offers valuable insights for other airports planning similar initiatives. One key takeaway is the importance of early and ongoing stakeholder engagement.

“Every department brought a unique perspective that enhanced the project,” Sonbuchner said. “The collaboration between design, construction, and operational teams was essential to our success.”

Lucas emphasized the role of pre-construction efforts in avoiding delays: “Establishing clear communication and schedules early on eliminated surprises during the build. It’s a best practice we apply to all our projects.”

For Berghage, the project highlighted the benefits of long-term planning. “This facility wasn’t just built for today—it was designed with future needs in mind,” he said. “That forward-thinking approach ensured we could address immediate challenges while preparing for growth.”

Wouda added that adaptability was crucial. “We learned that flexibility in design and execution is key,” he said. “No two airports are the same, and you have to tailor solutions to fit your unique needs.”

A Foundation for the Future

The expanded Snow Removal Equipment building at Gerald R. Ford International Airport represents more than just additional square footage. It’s a strategic investment in safety, efficiency, and the future of air travel. By centralizing operations, incorporating innovative design, and planning for growth, the airport has set a new standard for winter readiness.

“This facility is the culmination of years of planning, collaboration, and hard work,”

As Michigan’s second-busiest airport, serving nearly 4 million passengers annually, Gerald R. Ford International Airport now has the tools it needs to handle winter storms with precision and reliability—ensuring safe, efficient operations for years to come.