Aircraft hangars – custom design and construction

Aircraft hangars, also known as Aircraft hangarsThese are specialised steel structures for the storage, technical handling, and servicing of aircraft. High structural span, appropriate height, precise hangar doors, and operational safety are crucial here.
W ON-Time Solutions Aircraft hangars are designed based on specific operational requirements, aircraft type, and site conditions, ensuring the facility meets rigorous technical and operational standards.

Do you have questions or concerns?

When is an aircraft hangar the best solution?

Hangar It is an essential facility wherever safe storage and handling of aeroplanes, helicopters, or other aircraft are required. A properly designed hangar protects equipment from the weather and allows for efficient technical servicing.

This solution is particularly beneficial for:

airports and landing strips,
air clubs and training centres,
air operators
Aircraft maintenance company.

Aircraft hangar project tailored to aircraft

Airport hangar project requires precise matching of the structure to the dimensions and weight of the aircraft to be serviced. Not only the area counts, but also the clear span and the functional layout of the entrances.

At the concept stage, we consider, among other things:

Wingspan and height of aircraft,
Types and methods of opening hangar doors
floor load capacity
layout of service and communication zones
Possibility of extending the hall in the future.

This approach minimises the risk of operational constraints. Do you need advice? Contact us!

Aircraft hangar construction ensuring safety and precision

We construct aircraft hangars using steel frame technology, which allows for large spans and high structural stability.

Depending on the requirements, the aircraft hangar can be prepared for:

hangar for aeroplanes and helicopters,
technical and service support halls,
properties with workshop and storage facilities
Hangar panels made of sandwich panels.
Heated or unheated objects.

Aircraft hangars from ON-TIME Solutions – equipment safety and investment control

ON-Time Solutions builds aircraft hangars for private and institutional investors.Experience in the design of large-span steel structures allows us to create safe, durable, and resilient facilities.

For the investor, this means a predictable schedule, cost control, and a facility that meets aviation requirements for many years. Check Our achievements.

Are you planning to build an aircraft hangar?

If you are planning to build an aircraft hall or hangar and require a structure tailored to specific aircraft and operational requirements, contact the ON-Time Solutions team at the concept stage. Also, check out our offer for Modular housing.

Call +48 512 683 681

Write: biuro@ontimesolutions.pl

Frequently asked questions about aircraft hangars

How to choose hangar dimensions for a fleet and development plans (wingspan, height, clear span)?

The starting point is the dimensions of the largest aircraft (wingspan, height, turning radius) and the fleet development plan. The key is to ensure adequate span without internal pillars and space reserves for technical maintenance, transport routes, and service areas. This way, the hangar does not limit operations today and does not necessitate costly reconstruction tomorrow.

How to design a hangar for maintenance, repair, and overhaul (MRO) and health and safety (H&S)?

For service areas, it is crucial to designate zones: vessel servicing, spare parts storage, tool room, staff facilities, and circulation routes. The floor load-bearing capacity, suspension points/installations, and work ergonomics for large-scale operations are also important. A well-designed layout reduces service time and increases personnel safety.

The primary factors influencing the cost of building an aircraft hangar, and how to control them, are: Factors Influencing Cost: * Size and Dimensions: This is the most obvious factor. A larger hangar will naturally require more materials, a more extensive foundation, and more labour, making it more expensive. The clear span required for the aircraft is a significant driver here. * Type of Construction: * Steel Frame Hangars: These are very common and often cost-effective for larger spans. The thickness and grade of steel, along with the complexity of the frame design, will impact cost. * Pre-engineered Metal Buildings (PEMBs): These can offer significant cost savings due to standardisation and factory production. * Concrete or Masonry Hangars: While very durable, these are often more expensive and time-consuming to construct, particularly for large structures. * Fabric-Covered Structures: These can be a more budget-friendly option, especially for temporary or less demanding uses, but may have limitations in terms of insulation and durability. * Foundation Requirements: The ground conditions will dictate the type and depth of the foundation required. Poor soil conditions (e.g., soft soil, high water table) can significantly increase foundation costs. * Door Systems: * Type of Door: Bi-fold, roller, sliding, or fabric hangar doors all have different cost implications. Larger and more complex doors (like hydraulic bi-fold or large fabric doors) are more expensive. * Automation: Motorised and automated door systems will add to the cost. * Insulation and Environmental Control: Hangars requiring specific temperature control (heating, cooling, ventilation) or insulation for noise reduction or protection of sensitive aircraft components will incur higher costs for materials and energy systems. * Ancillary Facilities: Any fit-out for offices, workshops, staff rooms, restrooms, or specialised storage within the hangar will add to the overall cost. * Site Preparation: Clearing the land, grading, drainage work, and utility connections (water, electricity, data) are all necessary site-specific costs. * Location and Accessibility: Remote locations or sites with difficult access for large construction vehicles and material delivery can increase logistical costs. Local labour rates and material availability also play a role. * Materials and Finishes: The quality and type of cladding, roofing materials, flooring (e.g., polished concrete vs. standard), and interior finishes will affect the price. * Regulatory Requirements and Permits: Building codes, aviation authority regulations, and local planning permissions can add design complexity and costs for compliance. * Design and Engineering: The complexity of the structural design, architectural features, and engineering calculations required will influence design fees. How to Control Costs: * Detailed Planning and Design: * Clear Specifications: Define your needs precisely from the outset. What size aircraft will it accommodate? What level of insulation is required? What utilities are needed? * Value Engineering: Work with your design team to identify areas where cost savings can be made without compromising essential functionality or safety. Explore alternative materials or construction methods. * Standardisation: Opting for standard pre-engineered building designs where possible can significantly reduce costs. * Competitive Bidding: * Obtain Multiple Quotes: Get detailed quotes from several reputable hangar construction companies. Ensure the specifications are identical for a fair comparison. * Negotiate: Don't be afraid to negotiate prices, especially if you have multiple competitive bids. * Phasing the Project: If budget is a major constraint, consider building the basic structure first and adding features like insulation, specialised flooring, or advanced environmental controls in later phases. * Material Selection: Carefully consider the long-term costs and maintenance associated with different material choices. A slightly higher upfront cost for more durable materials might save money over time. * Efficient Door Systems: Choose a door system that meets your operational needs without being unnecessarily extravagant. Simpler, robust designs often perform just as well. * Minimising Site Obstacles: Thorough site surveys to identify potential issues can help avoid costly surprises during construction. * Strong Project Management: * Regular Site Visits: Keep a close eye on progress and quality. * Budget Tracking: Monitor expenses closely against the budget throughout the project. * Communication: Maintain clear and consistent communication with your contractor to address any issues promptly. * Focus on Essential Features: Prioritise features that are critical for the hangar's primary function and your operational needs. Non-essential aesthetic enhancements can be deferred if necessary. * Consider Long-Term Operating Costs: While initial cost is important, also consider the energy efficiency, maintenance, and lifespan of materials. A cheaper initial build might lead to higher running costs.

The cost is mainly determined by: the span and height of the structure, the type of gate, the standard of cladding (e.g. sandwich panel), temperature requirements (heating/ventilation), floor load capacity, and the level of equipment (service areas, installations). Cost control begins with clear operational assumptions and a design that eliminates "during-project" changes and streamlines prefabrication and assembly.

Why should you commission a hangar from a single "design and build" contractor?

In aircraft hangars, junction points are critical: structure–door–cladding–installations. A single contractor minimises the risk of design clashes, division of responsibility, and construction delays. For the investor, this means greater predictability of schedule, costs, and quality.

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