Aircraft hangars provide optimal protection for aircraft maintenance, ensuring efficient and smooth operations for engineers and technicians. They must meet the rigorous demands of the aviation maintenance industry, and provide ample space for one or more aircrafts, as well as maintenance teams.
This guide will explore the various sizes, dimensions, and layouts available for aircraft hangars, and help you in your own aircraft hangar design planning.
Popular Hangar Sizes
Aircraft hangars come in various sizes to accommodate different aircrafts—from propeller planes to commercial jets. You can also purchase a helicopter hangar design that fits one or more helicopters for private or commercial use.
There are three standard dimensions for aircraft hangar design:
| Hangar Size | Aircraft Type | Estimated Cost |
|---|---|---|
| 40x60 ft | Single propeller plane | $70 to $180/sq.ft. |
| 60x80 ft | Small commercial aircraft | $50 to $150/sq.ft. |
| 200x400 ft | Large commercial jet | $30 to $120/sq.ft. |
The larger an aircraft hangar, the more it costs to make. The wingspan and length of the aircraft must be considered to determine the appropriate dimensions and layout. There must also be sufficient room to meet clearance requirements and aviation standards.
The size of an aircraft hangar is a crucial factor, as it will determine how successful and seamless your operations will be. Shelter Structures will work with you in your aircraft hangar design to ensure you have the right specifications, whether you own a small personal aircraft or a fleet of jets.
Important Hangar Sizing Considerations
When you are designing an aircraft hangar, it is important to explore the different factors that need to be considered when selecting a size, such as:
Aircraft Dimensions
The dimensions of the aircraft or aircrafts that will be housed in the hangar will play a large role in the final airport hangar design. The aircraft’s wingspan, length, and height all play a significant factor in determining the appropriate hangar size based on National Fire Protection Association standards.
NFPA 409 outlines four different hangar classes based on the size and construction of the aircraft. Smaller aircrafts require less space and are therefore more cost-effective to build and maintain.
Multiple factors go into the final design specifications for a hangar, such as the height of the tail, the height and width of the hangar doors, and the height of the columns and trusses . It is important to also ensure that hangar design meets any specifications laid out by the organization, such as the United States Air Force.
Number of Aircrafts to Be Stored
Storing multiple aircrafts in the same hangar requires a thoughtful design that considers not only the size of the aircrafts but mobility as well. Traffic flow is a key consideration for multi-aircraft hangars, and there has to be enough room for planes or helicopters to safely move in and out.
Furthermore, the location of security gates and runways will also impact the design. Aircraft that belong to a commercial facility will have greater needs for navigation than small ones for personal use, but it is important to consider the requirements of every individual airport.
Maintenance and Repair Requirements
Hangar size and maintenance go hand in hand, particularly in busy airports. Maintenance staff need adequate space to safely perform services and repairs on an aircraft, and the hangar should have enough room to not only accommodate their movements but the transport of various tools and supplies as well.
Good aircraft hangar design incorporates sufficient room for maintenance workflows, ensuring a steady traffic flow that does not disrupt or delay departures or arrivals. Moreover, the hangar must provide adequate coverage to protect workers from the weather in hot and cold seasons, ensuring they always have a safe, dry space to perform their duties.
Future Expansion Plans
Some aircraft hangars can be expanded, and if your business intends to scale in the future, it will affect the initial layout and design. There are various factors to consider when building an aircraft hangar for future expansion, such as airport ownership and governance.
Many airport hangars are government property, and expansion requires filing petitions and attending public hearings. The scale of expansion may also be limited depending on the use and location of the hangar.
Furthermore, the design team must ensure that the hangar they build makes it as easy as possible for future expansions to accommodate more aircraft.
Layout Planning
An optimal hangar design will prioritize efficiency at every angle, including general use and daily administration and maintenance needs. There has to be adequate space for the aircraft to safely enter and leave the hangar, as well as ample storage for the equipment and tools needed to maintain the aircraft.
Additionally, there may need to be separate office administration spaces for engineers, technicians, and other personnel to safely work in the hangar. These factors will all be taken into consideration when designing the best layout.
Additional factors to consider in a good airplane hangar design are:
Zoning and Logistics
There should be clear operational zones in the design plan that highlight where maintenance members can service the aircraft. Each zone should have a specific purpose, such as repairs and storage of tools and equipment. Traffic flow is vital when designating these areas, as they will have a direct impact on the overall safety and efficiency of the hangar.
Hangar Doors and Other Access Points
The design team must ensure that a hangar has properly sized doors to safely accommodate aircraft entrances and exits. The doors should be able to easily fit the largest aircraft in the fleet, and they should provide sufficient girth on either side to prevent accidental clippings or damage to the aircraft or hangar.
Additional access points give staff easy and safe entry and exit from the hangar. They can also be designed to fit various equipment needed to service the aircraft. Most importantly, access points should be designed strategically to maximize operational efficiency.
Miscellaneous Spaces
Every hangar has unique needs depending on its location, purpose, and structure. A custom hangar design needs to suit the needs of the people working in it, whether they are engineers or military personnel.
The ideal aircraft hangar design will be in line with the needs of its staff and offer ample office space, maintenance rooms, and storage facilities as needed.
Aircraft and Personnel Circulation
In addition to the physical properties of the hangar layout, circulation throughout the hangar must also be considered in the design process. There must be enough clearance for airplanes or helicopters to safely arrive and depart without placing anyone in danger or damaging equipment. Additionally, there must be enough space for the entire staff to safely navigate the facility while servicing the aircraft.
Safety Precautions
Safety plays a critical role in plane and airport hangar design. There are major factors the design team has to address to ensure everyone’s well-being:
- Fire suppression systems according to NFPA 409
- Emergency exit routes that are easily accessible at all times
- Adequate ventilation systems to manage fumes and air quality
- Safety signages to protect workers and anyone in the hangar
Rest assured, the professional team at Shelter Structures constructs every hangar design with maximum safety in mind.
Aircraft Hangar Design Aspects
There are many design options available to give an organization the best hangar for its needs. For example, the T hangar design creates a nest configuration that allows aircraft of multiple sizes to be easily stored in the same facility. T hangars can be customized to be smaller or larger, depending on the needs of the company and the sizes of the aircraft.
Various design aspects play a role in both the look and function of an aircraft hangar, such as materials, doors, floors, and lighting.
Structural Features
The two main types of aircraft hangar materials are aluminum and reinforced concrete. Aluminum aircraft hangars are easier to build and dismantle than their concrete counterparts, but they are not ideal in areas that experience frequent tornadoes, hurricanes, or strong winds.
Doors can be made to slide, fold, or roll up depending on the size and scale of the hangar. Sliding doors are best for large hangars while folding doors can be used to save space.
The placement of the hangar doors is vital to ensuring safe hangar operations. It’s important that the design team calculates the hangar’s dimensions and considers the layout of the airport to ensure efficiency in arrivals and departures.
When it comes to flooring, all aircraft hangars need to feature durable, anti-skid materials that can withstand the immense weight of an aircraft. Concrete and epoxy are the most common hangar floor materials that deliver exceptional performance, durability, and protection.
For hangar lighting, both standard and emergency lighting systems are important. LED is the most common type of lighting used in hangars due to its long-lasting performance and low operating cost.
Utilities and Comfort
Aircraft hangar designs also include utilities that improve the comfort and function of the space. Modern aircraft hangars feature electricity, water, and WiFi, along with additional amenities including conference rooms, office spaces, employee lounges, and kitchenettes.
Cost Considerations
The cost of an airplane hangar can vary significantly depending on size, the materials used, and any additional amenities. The cost is also related to the wind and snow loads at the location where the hangar is to be built, the higher the wind and snow loads the more the hangar will need to be reinforced. There are various rental and purchase options available that can help balance the budget for any company building a custom hangar.
When it comes to pricing, size will play the biggest factor. Larger hangars cost more to construct and maintain, so they pose increased costs not just in the initial investment but over the course of their lifespan.
Smaller hangars are more affordable to build, but they might pose limitations for an airport or hangar that needs to accommodate more than one aircraft or needs additional space for amenities and equipment.
Location will also affect how much a hangar costs as construction needs vary from one area to another, especially on undeveloped land.
A hangar is a significant investment, but it also poses the potential benefit of earning revenue through hangar rentals. Larger hangars can increase earning potential and be worth more as capital, so determining the ideal design really depends on each organization’s structure, needs, and long-term goals.
Good Design, Good Quality
The goal of any hangar is to ultimately provide a safe, secure structure for aircraft owners and operators, as well as any staff who perform maintenance and repairs. A good aircraft hangar design meets all the business requirements and key aviation standards. Explore Shelter Structures airplane hangar designs, which range from small, private hangars to airport-ready designs.
