Aviation development projects are complex by nature. From airport coordination and FAA requirements to lease structuring, capital alignment, aircraft-driven design, and construction execution, successful hangar development requires every piece to work together from the beginning. ARCO National Construction brings those elements into a single, coordinated process to help aviation clients move projects from concept to completion with greater speed, clarity, and certainty.
Aligning Development, Capital & Construction
Many aviation projects stall because development strategy, financing, and construction execution are handled separately. Misalignment between those teams can create delays, cost increases, redesigns, and entitlement challenges later in the process. ARCO’s integrated approach helps eliminate those gaps by aligning development, capital planning, and design-build delivery from day one.
ARCO’s aviation team works alongside owners, operators, developers, and airport stakeholders to create a fully executable project path that supports both operational goals and long-term financial viability. The process includes:
- Site control and airport coordination
- FAA and entitlement navigation
- Lease structure evaluation
- Capital sourcing strategy
- Design-build execution
- Cost and schedule planning
This collaborative approach creates a single accountable team from early planning through final delivery.
“Airports need a project that clears FAA constraints, fits the lease structure, and is financeable from day one. We structure the deal so it works with the airport, the tenant, and the capital stack because if it doesn’t pencil, it doesn’t get built.” – Scott Rightnowar, Head of Commercial Aviation
Designing Around the Aircraft
Successful hangar development starts with understanding how aircraft will move, operate, and be serviced within the facility. Rather than forcing operations into a predefined building layout, ARCO prioritizes aircraft-driven geometry and operational flow early in planning.
Key design considerations include:
- Door orientation tied directly to taxiway and apron access
- Apron depths designed around maneuvering requirements
- Integrated support spaces planned during schematic design
- Facility layouts optimized for aircraft servicing and circulation
By coordinating these factors early, projects can avoid costly redesigns later in the process while improving long-term operational efficiency.
Understanding Hangar Development Costs
Aviation facilities vary significantly depending on aircraft type, operational requirements, fire protection systems, and specialized infrastructure. ARCO helps clients establish realistic budgets early while identifying the primary cost drivers that influence project scope.
Major cost considerations often include:
- Hangar door systems
- Fire protection requirements
- Mechanical systems
- Apron construction and paving
Early alignment between development assumptions and construction realities helps create more financeable and executable projects.
“We take hangars from concept to guaranteed cost early, so you’re not designing a $500-per-foot building and discovering at bid it’s $650. ARCO’s approach is really about eliminating surprises: an aligned design, real-time pricing, and a schedule you can actually build to.” – Parker Snyder, Director of Business Development
Structuring Facilities for Long-Term Success
Hangar development is not only a construction challenge — it is also a long-term operational and financial decision. ARCO works with clients to align facility planning with lease structures, development pro formas, and long-term operating goals.
Common aviation development considerations include:
- Developer-owned facilities with long-term lease structures
- CPI escalation planning
- Free-rent periods during construction
- Financing structures aligned with realistic cost and schedule expectations
By evaluating development feasibility alongside design and construction strategy, aviation stakeholders can make more informed decisions earlier in the process.
A Coordinated Approach to Aviation Development
Whether developing a maintenance hangar, paint facility, corporate aviation center, or large-scale MRO campus, aviation projects demand coordination between multiple stakeholders and technical disciplines. ARCO’s integrated model helps streamline communication, improve accountability, and reduce disconnects between planning, financing, and execution.
With experience supporting aviation clients across development strategy, airport coordination, design-build delivery, and facility execution, ARCO helps clients navigate the complexities of hangar development with a process built around certainty, efficiency, and operational performance.
View the presentation from MRO Americas here.
ABOUT ARCO NATIONAL CONSTRUCTION
ARCO National Construction is a design-build contractor with extensive experience in aviation and aerospace facilities, including aircraft hangars, MRO facilities, and airport developments nationwide. Through an integrated delivery approach, ARCO provides cost certainty, streamlined coordination, and facilities designed to meet operational, FAA, and NFPA requirements while supporting long-term performance.
