Aircraft Hangar Buildings
Large clear span aviation facilities engineered for aircraft storage, maintenance, and FBO operations. Gonzales Construction delivers comprehensive design-build hangar solutions with clear spans to 220 feet standard and special engineered systems exceeding 500 feet, combining the structural performance aviation demands with the project delivery efficiency your timeline requires.
- Clear Spans to 220 Ft
- Custom Door Systems
- PE Stamped Engineering
220+ Ft
Standard clear span capability for unobstructed aircraft access
500+ Ft
Special engineered systems for the largest aviation requirements
Since 1960
Decades of aviation facility experience across California
100%
Custom engineered to your aircraft fleet and operational needs
Aviation Facilities Engineered for Performance
Aircraft represent significant capital investments requiring protection from weather, UV exposure, and security threats. Our pre-engineered hangar buildings deliver the expansive clear span interiors, specialized door systems, and durable construction that aviation operations demand, all backed by design-build delivery that coordinates engineering, permitting, and construction under single-source accountability.
Why Steel for Aviation Facilities
Unmatched Clear Spans
Pre-engineered rigid frame construction delivers clear span widths impossible with conventional framing. Standard systems provide unobstructed interiors to 220 feet, while special engineered hybrid systems combining building system efficiency with conventional steel can exceed 500 feet for the largest commercial and military applications.
High Eave Heights
Accommodate aircraft tail heights and overhead crane systems with eave heights engineered to your specific requirements. From single-engine private aircraft to wide-body commercial jets, we design vertical clearances that provide safe access and operational flexibility for your entire fleet.
Integrated Door Systems
Hangar doors represent critical operational components requiring careful engineering coordination. We integrate bi-fold, hydraulic, rolling, and stacking door systems into the primary structure, ensuring proper header design, weathersealing, and operational reliability for daily aircraft movement.
Multi-Use Space Integration
Modern aviation facilities require more than aircraft storage. Our designs integrate mezzanine levels, office suites, pilot lounges, maintenance bays, and parts storage into cohesive layouts that maximize operational efficiency while maintaining the clear span floor space aircraft operations require.
Navigating Aviation Requirements
Aviation construction involves unique regulatory and coordination requirements beyond standard commercial projects. Our team understands airport authority approval processes, FAA coordination requirements, security protocols, and the operational constraints of working on active airfields.
We work within your airport’s requirements while delivering facilities that meet both regulatory standards and operational objectives.
Manufacturer Partnership
As an authorized builder for American Buildings Company, a NUCOR company, we provide direct access to engineering resources specifically experienced in aviation facility design, backed by comprehensive manufacturer warranties and technical support throughout your project.
Aviation Facility Applications
Our hangar and aviation building expertise spans the full range of industry applications, each engineered for the specific operational demands of your facility type.
Aircraft Storage Hangars
Purpose-built structures protecting aircraft investments from weather, UV degradation, and security threats. Clear span designs maximize parking density while wide door openings allow efficient aircraft movement without wing walker constraints.
Key Features:
- Clear spans to 220+ feet
- Bi-fold and hydraulic door systems
- Climate control options
MRO and Maintenance Facilities
Maintenance, repair, and overhaul facilities designed for productivity and safety. Layouts accommodate aircraft positioning, maintenance stand access, parts flow, and specialized systems including overhead cranes, compressed air distribution, and hazardous material containment.
Key Features:
- Overhead crane integration
- Reinforced floor systems
- Specialized utility distribution
FBO Facilities
Integrated fixed-base operator complexes combining aircraft storage, passenger services, and operational support under coordinated designs. Facilities balance the industrial requirements of aircraft operations with the customer experience expectations of premium aviation services.
Key Features:
- Integrated terminal space
- Pilot lounge and amenities
- Fuel system coordination
Corporate Flight Department Hangars
Executive aviation facilities reflecting corporate standards while protecting valuable aircraft assets. Designs integrate finished office environments, crew facilities, and aircraft storage in layouts that project professionalism while maintaining operational efficiency.
Key Features:
- Premium interior finishes
- Executive office integration
- Enhanced security systems
Helicopter Facilities
Rotorcraft facilities accommodating the unique dimensional and operational requirements of helicopter operations. Designs address rotor clearances, fuel system requirements, and the rapid deployment needs of emergency medical, law enforcement, and utility helicopter services.
Key Features:
- Optimized rotor clearances
- Rapid deployment layouts
- Helipad integration
Agricultural Aviation
Aerial application facilities combining aircraft storage with chemical handling, mixing, and loading operations. Designs address containment requirements, wash rack drainage, and the seasonal intensity of agricultural aviation operations.
Key Features:
- Chemical containment systems
- Loading area integration
- Wash rack drainage
Hangar Door Systems
The door system represents one of the most critical components of any aircraft hangar. We engineer and coordinate door integration from initial design through installation, ensuring proper structural support, weathersealing, and operational reliability.
Bi-Fold Doors
Hydraulically operated bi-fold systems provide full-width openings with relatively compact stacking height. Ideal for hangars where apron space is limited or where operational simplicity is prioritized. Available in bottom-rolling and top-supported configurations.
Hydraulic One-Piece Doors
Single-panel hydraulic doors lift vertically for maximum clear opening width. These systems minimize threshold obstructions and provide clean aesthetic lines, making them popular for corporate and FBO applications where appearance matters.
Rolling/Sliding Doors
Multi-leaf rolling doors slide horizontally along the hangar face, stacking at one or both ends. These systems accommodate very large openings and provide operational flexibility for partial opening configurations during inclement weather.
Stacking Doors
Vertical stacking systems lift door panels and stack them above the opening, providing maximum clear width without side stacking space requirements. Ideal for sites with constrained building footprints or multiple adjacent hangars.
Segmented Doors
Sectional overhead doors offer cost-effective solutions for smaller openings and personnel access. Available in insulated configurations for climate-controlled facilities, these doors complement primary aircraft door systems.
Custom Configurations
Unique operational requirements sometimes demand custom door solutions combining multiple system types or incorporating specialized features. Our engineering team works with leading door manufacturers to develop configurations meeting your specific needs.
Hangar Design Features
Beyond basic aircraft storage, modern hangars incorporate numerous features supporting operations, safety, and long-term value. Our engineering team integrates these elements into cohesive designs.
Mezzanine Levels
Maximize facility value by adding second-level space for offices, parts storage, crew quarters, or tenant improvements. Mezzanines are engineered as integral structural components, not afterthoughts, ensuring code compliance and optimal space utilization.
Overhead Crane Systems
MRO and heavy maintenance operations often require overhead crane capability for engine removal, component handling, and aircraft jacking support. We coordinate crane system requirements with primary structural design from project inception.
Fire Suppression Systems
Aviation facilities present unique fire protection challenges due to fuel presence and high-value assets. We coordinate with fire protection engineers to integrate foam suppression, sprinkler systems, and detection equipment appropriate for your facility classification.
Insulation and Climate Control
Protect aircraft finishes and maintain comfortable working conditions with insulation systems matched to your climate and operational requirements. Options range from basic condensation control to fully climate-controlled environments for sensitive maintenance operations.
Lighting Systems
Proper illumination supports safe aircraft movement, maintenance quality, and energy efficiency. We integrate natural daylighting through translucent panels with LED fixture layouts designed for aviation facility requirements and energy code compliance.
Utility Distribution
Aircraft maintenance requires strategically located power, compressed air, nitrogen, and other utilities. Our designs incorporate utility distribution planning that supports operational workflow without creating floor obstructions or safety hazards.
Frequently Asked Questions
Common questions about aircraft hangar construction, from clear span capabilities and door systems to airport coordination and project timelines.
What is the maximum clear span available for aircraft hangars?
Our standard pre-engineered building systems provide clear spans up to 220 feet. For larger requirements, we design special engineered hybrid systems combining building system efficiency with conventional steel construction, achieving clear spans of 500 feet or more for commercial and military applications.
How do you coordinate with airport authorities during construction?
We work within established airport construction protocols, coordinating with airport operations, security, and facilities management throughout the project. This includes scheduling around flight operations, maintaining security compliance, managing airfield access, and meeting all airport authority approval requirements.
Can hangars accommodate multiple aircraft sizes?
Yes. We design hangars considering your current fleet and anticipated future aircraft. Clear span widths, eave heights, and door opening dimensions are engineered to accommodate the largest aircraft you plan to house, while interior layouts can be configured for efficient multi-aircraft storage.
What door system is best for my hangar application?
Door system selection depends on opening width, available stacking space, operational frequency, climate conditions, and budget. Bi-fold systems offer simplicity and moderate cost, hydraulic one-piece doors provide clean aesthetics, and rolling doors accommodate the largest openings. We evaluate your specific requirements to recommend the optimal solution.
How long does hangar construction typically take?
Timeline varies significantly based on hangar size, complexity, and site conditions. A straightforward single-aircraft corporate hangar might be completed in four to six months from contract, while large MRO facilities or FBO complexes require 12 to 18 months or more. We provide detailed schedules during project planning, accounting for engineering, permitting, fabrication, and construction phases.
Are your hangars engineered for California seismic requirements?
Absolutely. Every building we construct is engineered to meet California seismic codes for your specific location. Despite the large clear spans involved, steel’s inherent flexibility combined with our rigid frame designs provides excellent earthquake resistance. All structural calculations are stamped by licensed California professional engineers.