Building Big: Custom Tension Fabric Hangars for Every Aircraft Need

Huge planes need huge spaces. Whether you’re looking to create a hangar for large-body executive jets, commercial passenger planes, or cargo aircraft, the only way to accommodate their sheer size in an unobstructed environment is with clear-span construction. A tension fabric building can be designed to fit any plane’s wingspan, length, and height plus clearances needed for safety and maneuverability. 

How Big is Big?

The most popular commercial aircraft are very large. However, airlines and cargo carriers are increasing their fleets of smaller aircraft to more efficiently handle regional routes with smaller airports. All of these planes vary in their dimensions depending on the manufacturer and model. For example, among the largest and most common models:

• Boeing says its 737 variants can have wingspans up to 117 feet, bodies up to 138 feet long and a tail height of 41 feet.
• On the Boeing 777, wingspans can stretch well over 200 feet. These models can be up to 200 feet long and a little more than 61 feet tall at the tail.
• Airbus says the A320 has a wingspan of 117 feet and can be upwards of 123 feet long and 38 feet tall.

Whatever the number and types of aircraft your hangar will serve, the process to create an optimal hangar is the same. You will need to consider:

• The aircraft involved
• Hangar door requirements
• Overall purpose of the facility 

Aircraft Specifications 

Obviously, your hangar must be large enough to allow the aircraft you serve to enter and maneuver safely. If your operation involves multiple aircraft, plan based on the dimensions of the largest model.

Consider the future, because things change and your hangar is a long-term investment. You can create a hangar large enough to handle current needs but also provide plenty of space for workflow expansion or even bigger aircraft. Designing with flexibility in mind can support a more versatile business model and be more cost-effective in the long run.

Hangar Doors

Some companies specialize in manufacturing hangar doors, which can lift upward or roll off to the side. Rolling or sliding doors can be up to 90 feet high. In sizing your doors, the recommended clearance is at least 5 feet in each direction, though some owners specify extra clearance for the wingspan. The manufacturer will provide detailed drawings for whatever door style and size you choose.

Overall Building Needs

When it comes to hangar design, each building is its own unique project. Location and other site specifics mean you can’t simply replicate a structure designed for one area and install it in other locales around the country (or the world). There are too many variables that influence the details of your design, so each building must be custom-designed to reflect its circumstances such as:

• Environmental loads–weather can significantly influence design requirements, especially in places vulnerable to hurricanes or where the environment is humid or salty
• Local zoning, land use laws, and building regulations
• Landowner requirements–most airline hangars and MRO facilities are located on property leased from the airport owner
• FAA regulations regarding hangar features and placement

And the building itself? A commercial hangar is more than a big barn. So, will this be an assembly facility, an MRO, aero storage, or part of a military installation? The overall purpose will determine the layout and indoor features. Think about:

• Collateral loads–cranes to lift aircraft parts, conveyors to transport baggage or cargo
• Type of aircraft tug equipment in use
• Type and configuration of access points for humans and vehicles
• Storage requirements
• Water mitigation systems (overhangs, gutters, downspouts, icebreakers)
• Passive or powered ventilation 

Get Exactly What You Want

Because every situation is different, custom construction is a must to achieve maximum functionality and safety. Legacy tension fabric buildings are always designed and manufactured one by one, because we know it’s often the details that determine long-term performance and efficiency. Each building is designed specifically for intended use and to withstand Mother Nature’s temper tantrums. 

Rigid steel I-beam construction allows us to design clear-span structures with any shape, wall length, eave height, or peak height. These buildings are strong enough to support hanging loads such as cranes, conveyors, and fire suppression systems, not to mention enormous, heavy hangar doors. Our ExxoTecTM tension fabric sidewall cladding is installed in panels that provide a seamless, airtight fit but can be replaced individually if damage ever occurs.

You can choose options such as lean-tos or insulation, in specific areas or throughout the building. And custom design also means you don’t pay for space you don’t need.

While our tension fabric buildings are engineered to be permanent, they can also be designed to be portable. This added flexibility can be a significant advantage, especially for military installations

What might your tension fabric hangar look like? Our Aviation Storage Solutions Book is filled with examples of our work with customers in the aviation industry. 

Shorter Time to Completion

The global fleet of commercial aircraft is expected to increase by 28% by 2036, and general aviation is growing at about the same rate. Those aircraft will require hangars for assembly, maintenance, and repair. Airports and MRO facilities are working as fast as possible to meet this increasing demand. At Legacy Building Solutions, every aspect of our in-house design/build/install process is geared toward faster completion without sacrificing details, quality, or craftsmanship.

Custom design and engineering is what we do every day at Legacy Building Solutions, so your tough challenge is our next interesting project. Our team has the knowledge and experience to help you create a fully functional hangar that will serve you efficiently now and give you the flexibility to grow as your business and the aviation industry change.