Aircraft Hangar Buildings

Design, Codes, and Construction Guide

Aaron Williams

September 4, 2025

Building an aircraft hangar requires specialized knowledge of aviation requirements, building codes, and structural engineering. At Indaco Metals, we've been manufacturing steel buildings since 1995. Our steel hangar buildings protect everything from single-engine aircraft to corporate jets and helicopters, combining the durability and span capabilities that aviation facilities demand nationwide.

Understanding Aircraft Hangar Requirements

Aircraft hangars are specialized structures with unique design challenges. Unlike typical commercial buildings, hangars must accommodate large door openings, significant clear spans, and specific fire safety requirements while withstanding challenging weather conditions.

Critical Design Factors

Every hangar project begins with understanding the aircraft it will house:

• Aircraft dimensions including wingspan, length, and tail height

• Door clearances with adequate margins for safe maneuvering

• Ceiling heights allowing for propellers, rotors, or vertical stabilizers

• Floor loading to support landing gear and maintenance equipment

Clear Span Requirements

Most aircraft require unobstructed interior spaces. Our rigid frame building systems excel at creating the large clear spans that airplane hangar construction demands:

• Single-engine aircraft: Typically require 40-60 foot spans

• Twin-engine aircraft: Usually need 60-80 foot clear spans

• Corporate jets: Often require 80-120 foot spans or larger

• Multiple aircraft: May need spans exceeding 150 feet

Aircraft Hangar Building Codes and Regulations

Federal Aviation Administration (FAA) Standards

For hangars located at public airports, the Federal Aviation Administration (FAA) sets additional nationwide requirements. These include Advisory Circular 150/5220-4B, which provides detailed hangar design guidance. The FAA also regulates fuel handling during aircraft servicing, requires proper airport layout coordination to ensure safe taxiway access, and enforces security measures within airport operations areas. Together, these standards create a consistent framework for safe hangar construction and use across the country.

State and Local Fire Marshal Requirements

Beyond federal oversight, state and local fire marshals add another layer of requirements for hangar safety. These codes often mandate foam fire suppression systems for larger hangars, along with strict fuel storage and containment rules. Facilities that perform welding or maintenance may also need hot work permits, and hangars must be designed with emergency response access in mind so that fire crews and safety equipment can be deployed quickly.

Steel Hangar Design Considerations

Door Systems

Hangar doors are often the most critical and expensive component, requiring careful selection based on your specific needs and budget constraints.

Door Type	Best For	Advantages	Considerations
Bi-Fold Doors	Medium to large hangars (60-150 foot openings)	Good wind resistance, reliable operation	Higher initial cost, requires adequate ceiling height
Sliding Doors	Smaller hangars with limited height restrictions	Lower cost, simpler operation	Side wall reinforcement needed, weather sealing challenges
Hydraulic Doors	Large corporate hangars with frequent use	Smooth operation, excellent sealing	Highest cost, requires maintenance expertise

Structural Engineering Requirements

Aircraft hangar steel buildings face unique structural challenges that require careful engineering consideration. Wind loads must resist severe weather conditions in various regions, with requirements varying significantly based on geographic location and local climate patterns. Snow and ice loading capacity becomes critical in northern climates, while seismic considerations under modern building codes require specialized design approaches nationwide.

Foundation requirements vary dramatically depending on regional soil conditions, from expansive clay soils in some areas to sandy conditions in coastal regions. Each location demands specific engineering solutions to ensure long-term structural integrity and proper load distribution for heavy aircraft storage.

Floor Systems

Aircraft hangar floors require special consideration:

• Concrete thickness: Typically 6-8 inches to support aircraft loads

• Reinforcement: Steel reinforcing prevents cracking under point loads

• Fuel resistance: Sealers protect against fuel spills

• Drainage: Proper slope and drains prevent standing water

Aircraft Hangar Sizing Guide

Proper sizing ensures adequate space for safe aircraft storage and maneuvering. The following dimensions represent minimum requirements, though additional space always improves safety and functionality.

Aircraft Category	Example Aircraft	Minimum Size	Recommended Size
Single-Engine	Cessna 172, Piper Cherokee, Cirrus SR22	40' x 30'	45' x 35'
Twin-Engine	King Air 200, Piper Seneca, Cessna 310	50' x 35'	60' x 45'
Light Jets	Citation Mustang, King Air 350	55' x 40'	65' x 50'
Mid-Size Jets	Citation X, Hawker 800	70' x 50'	80' x 57'

How Much Does It Cost to Build an Aircraft Hangar?

Aircraft hangar construction costs vary significantly based on size, features, and location. Understanding these cost factors helps you budget effectively for your aviation facility project.

Base Building Costs

Steel hangar buildings offer predictable pricing compared to traditional construction methods:

Aircraft hangar construction costs vary significantly based on size and features:

• Basic steel structure: $15-25 per square foot

• With standard doors: $25-40 per square foot

• Fully finished hangar: $40-80 per square foot

• Corporate facilities: $60-120+ per square foot

Door Cost Considerations

Hangar doors represent a significant portion of total cost:

• Sliding doors: $8-15 per square foot of opening

• Bi-fold doors: $15-25 per square foot of opening

• Hydraulic doors: $20-35+ per square foot of opening

Site Development Costs

Aviation facilities require specialized site work nationwide:

• Aircraft-rated concrete: $6-12 per square foot

• Taxiway connections: Varies based on airport requirements

• Fuel systems: $15,000-50,000+ depending on complexity

• Electrical systems: Must meet aviation-specific codes

Regional Building Considerations

Structural Design Requirements

Aircraft hangar buildings must meet specific structural requirements based on their location and intended use. Regional building codes establish minimum standards for wind resistance, seismic considerations, and load-bearing capacity that vary by geographic location. Steel construction provides excellent structural integrity while accommodating the large clear spans required for aircraft storage.

Foundation design depends on local soil conditions and requires engineering analysis to ensure adequate support for both the building structure and aircraft loads. Proper structural design ensures long-term building performance while meeting all applicable safety requirements and building codes.

Local Airport Regulations

Aviation facilities must coordinate with various regulatory bodies throughout the planning and construction process. State transportation departments maintain specific aviation requirements that vary significantly by location, often reflecting regional priorities and safety concerns. Individual airports maintain their own standards and operational procedures that can impact everything from building placement to architectural requirements.

Federal FAA requirements apply to airport-located hangars regardless of location, while insurance companies frequently mandate specific construction standards that may exceed local building codes. Understanding this regulatory landscape early in the planning process prevents costly delays and design modifications later in the project.

Utility and Infrastructure Requirements

Electrical Systems

Aircraft hangars have specialized electrical requirements that differ significantly from typical commercial buildings. Aircraft power systems require 110V and 220V connections along with specialized aviation electrical systems for ground power and battery charging. High bay lighting designed for aircraft maintenance provides adequate illumination for detailed work, while HVAC systems maintain climate control for both aircraft protection and human comfort. Emergency backup power systems and emergency lighting ensure safety during power outages and provide compliance with aviation safety regulations.

Plumbing and Drainage

Hangar utility requirements include specialized drainage systems with oil separators required for floor drains in maintenance areas to prevent environmental contamination. Fuel containment systems provide spill prevention and containment capabilities, meeting environmental protection standards for aviation fuel handling. Water supply systems serve multiple purposes including aircraft washing stations and fire suppression system connections, while compressed air systems provide essential support for aircraft maintenance activities and tire inflation requirements.

Fire Suppression Systems

Fire protection requirements depend on hangar size, intended use, and local fire codes. Automatic sprinkler systems become mandatory for hangars exceeding certain size thresholds as defined by local building codes. Foam suppression systems often receive requirements for aircraft fuel fire protection, providing specialized fire suppression capabilities beyond standard water-based systems.

Portable fire suppression equipment must include extinguishers specifically rated for aircraft fires, while alarm systems require connection to airport fire departments or local emergency services to ensure rapid response during emergencies.

Permitting and Approval Process

Building Permits

Aircraft hangar construction requires coordination with multiple regulatory agencies and permit authorities. Building permits through local jurisdictions represent the primary approval required, though requirements vary significantly between municipalities and counties. FAA Form 7460-1 must be filed for structures near airports to ensure compliance with airspace protection requirements and flight safety regulations.

Environmental review processes may be required for hangars near airports, particularly those involving fuel storage or maintenance activities. Fire department approval becomes necessary for suppression systems and emergency access planning, ensuring adequate fire protection and emergency response capabilities.

Airport Coordination

Hangars constructed at public airports require additional layers of approval and coordination beyond standard building permits. Airport layout plan amendments may be necessary to accommodate new structures, requiring coordination with airport management and potentially FAA approval depending on the scope and location of the proposed hangar.

Lease agreements establish terms for airport property use, typically involving long-term commitments and specific operational requirements. Airport architectural design standards often mandate specific aesthetic requirements to maintain visual consistency across airport facilities. Operational approvals for taxiway access and aircraft operations ensure safe integration with existing airport traffic patterns and procedures.

Maintenance and Lifecycle Considerations

Steel Hangar Advantages

Aircraft hangar steel buildings offer significant long-term benefits for aircraft storage and operational efficiency. Durability stands out as a primary advantage, with 40+ year manufacturer warranties on metal roofing systems providing long-term value and peace of mind. Low maintenance requirements compared to traditional construction materials reduce operational costs over the building's lifetime.

Expansion capability allows for easy modification or expansion as aircraft fleets grow or operational needs change. The strong resale value of well-built steel hangars reflects continued market demand for quality aviation facilities, making them sound long-term investments for aircraft owners and airport operators alike.

Preventive Maintenance

Regular maintenance preserves hangar value and ensures continued operational reliability. Door system maintenance requires annual inspection and lubrication to maintain smooth operation and prevent costly repairs. Roof maintenance includes regular gutter cleaning and panel inspection to prevent water damage and maintain structural integrity.

Floor care involves regular cleaning and periodic resealing as needed to protect against fuel spills and maintain appearance. HVAC system maintenance includes routine filter changes and equipment servicing to ensure consistent climate control and energy efficiency throughout the facility's operational life.

Design and Construction Process

Initial Planning Phase

Successful aircraft hangar construction begins with thorough planning that addresses both immediate needs and future growth potential. Current and planned aircraft inventory drives initial sizing decisions, while site evaluation examines soil conditions, available utilities, and airport access requirements that can significantly impact construction costs.

Code research encompasses all applicable federal, state, and local regulations, which can vary substantially between jurisdictions. Budget development requires realistic cost estimates that account for all project phases, from initial site preparation through final occupancy, including potential cost variations based on regional labor and material pricing.

Design Development

Our team works with you to create functional aircraft hangar designs that meet both current needs and future expansion possibilities. Architectural planning addresses aesthetic and functional requirements while ensuring compliance with aviation-specific building codes and airport design standards. Structural engineering incorporates regional wind and seismic design requirements, ensuring building integrity under local environmental conditions. Mechanical systems design encompasses HVAC, electrical, and plumbing systems specifically configured for aviation use, while permit preparation includes complete drawing sets formatted for regulatory approval processes.

Construction Management

Aircraft hangar construction requires specialized expertise throughout the building process. Foundation work proves critical for proper door operation, requiring precise elevation and alignment to ensure smooth door function over the building's lifetime. Steel erection demands exact assembly techniques for proper fit and structural function, particularly important given the large spans and specialized loads typical in aviation facilities.

Door installation requires experienced aviation door specialists familiar with the unique requirements and operational characteristics of hangar door systems. Final systems completion encompasses electrical, mechanical, and fire suppression installation and testing to ensure full operational readiness upon project completion.

Working with Indaco Metals for Your Hangar Project

As a premier steel building manufacturer, we bring decades of aviation construction experience to your aircraft hangar construction project. Our aviation expertise encompasses understanding of aircraft requirements and aviation codes nationwide, while our regional knowledge includes familiarity with various airport regulations and requirements across different jurisdictions.

We provide complete solutions from initial design consultation through final construction completion, using quality materials engineered to withstand challenging weather conditions regardless of your geographic location. This comprehensive approach ensures your project meets all regulatory requirements while staying within budget and timeline constraints.

Our Aircraft Hangar Services

We offer free consultations to assess your aircraft storage and facility needs, working closely with you to understand both current requirements and future expansion plans. Our custom design services incorporate aviation-specific requirements nationwide, ensuring compliance with federal regulations while meeting local code requirements.

Engineering services guarantee code compliance and structural integrity throughout the design and construction process. We also provide comprehensive project coordination with airports, contractors, and regulatory agencies, streamlining the approval process and ensuring smooth project execution from start to finish.

Use our 3D Builder tool to begin visualizing your hangar design and explore configuration options.

Getting Started with Your Hangar Project

Ready to protect your aviation investment with a quality steel hangar building? Contact our sales team to discuss your specific aircraft storage needs. We'll help you navigate the complex requirements of aircraft hangar construction while staying within your budget.

Visit our showrooms in Shawnee or Sand Springs to see our building materials and discuss your project with our aviation construction experts. With nearly 30 years of experience serving the aviation community, we're ready to help you build a hangar that protects your aircraft for decades to come.

Contact Information:

• Shawnee Location: 3 American Way, Shawnee, OK 74804 - (405) 273-9200

• Sand Springs Location: 17427 W 9th St, Sand Springs, OK 74063 - (918) 419-6053

• Online: Request a quote online

Whether you're storing a weekend flyer or a corporate jet, we'll help you build the perfect hangar for your aviation needs.