Design-build solutions for successful aircraft hangar & aviation construction

Strategic planning is the crucial first step in your aviation project. Site selection should support easy access to selection should support easy access to runways and taxiways, minimize towing distances, and align with the airport’s broader operational flow. Evaluating soil conditions, nearby structures, utilities, and transportation access helps ensure the site is truly ready for development. Regulatory considerations, including FAA, ICAO, environmental impact requirements, and local permitting, should also be addressed early to avoid delays.

ARCO is involved in the earliest stages of aviation projects to provide accurate early budgeting, constructability insights, and regulatory coordination to help you make confident, well-informed decisions from day one.

Widebody hangars and large MRO facilities rely on clear-span structural systems that maximize space, eliminate interior columns, and support safe aircraft movement. Long-span steel frames, trusses, and space frames are engineered to withstand wind, snow, seismic forces, and heavy operational equipment.

High-strength, corrosion-resistant materials help reduce long-term maintenance costs, while prefabricated components can streamline the construction schedule. Doors, whether hydraulic, bifold, or rolling, must accommodate aircraft wingspans and tail heights while supporting energy efficiency and weather protection.

ARCO has the in-house structural resources and national subcontractor network to design the most efficient long-span solution for each aircraft type and operational need of your business, balancing cost, performance, and speed to market.

Aviation facilities operate best when the interior layout supports smooth workflow and easy movement. Hangars need clear maneuvering zones and optimized staging areas; MRO shops require efficient access to tools and parts; and cargo buildings rely on strategic sorting and loading zones.

Future-proofing is equally important. Flexible layouts make it easier to add docking bays, update technology, or expand as operations grow.

ARCO works closely with owners, operators, and airport stakeholders to create customized layouts that enhance current productivity while allowing for scalable, cost-effective expansion in the future.

Efficient MEP systems are critical to the functionality of a hangar. HVAC systems should use zoned controls to optimize energy use while maintaining comfortable working conditions. Advanced filtration systems are essential to remove fumes and particulates from maintenance activities, and natural ventilation solutions like operable louvers can enhance airflow. Lighting systems should include high-efficiency LEDs with motion sensors to reduce energy consumption, supplemented by skylights or translucent panels for natural daylighting. Drainage systems need to manage fuel, oil, and water runoff effectively, incorporating trench and grate designs. Water reclamation systems can be used to recycle water for non-potable purposes like aircraft washing, ensuring compliance with environmental standards for wastewater treatment.

ARCO integrates advanced MEP systems into the design early, ensuring aviation facilities operate safely, efficiently, and sustainably, with solutions tailored to your environment, climate, and operational profile.

Safety is central to every aviation facility. Hangars, MRO bays, and cargo buildings often require specialized fire suppression systems like high-expansion foam or water mist, along with fire-resistant materials and clearly marked evacuation routes.

Redundant electrical systems help keep critical operations running, and modern security infrastructure such as RFID or biometric access, CCTV, motion sensors, and cybersecurity protections, must integrate seamlessly with airport-wide protocols.

ARCO’s rigorous safety standards and deep knowledge of FAA, NFPA, and airport compliance requirements help reduce risk, streamline approvals, and ensure every facility is built to meet or exceed regulatory expectations.