ARCO National Construction Provides Cost & Schedule Saving Solutions for Aircraft Hangar Project

ARCO National Construction is currently delivering a highly specialized aircraft hangar and aerospace coatings facility for International Aerospace Coatings (IAC) in Amarillo, Texas. Located within an active airport environment, the project requires extensive coordination with federal, state, and local agencies while maintaining strict cost and schedule control.

Designed to support advanced aircraft painting and finishing operations, the facility incorporates specialized mechanical systems, hazardous material handling areas, and aviation-grade infrastructure. ARCO is utilizing its design-build expertise in Texas aviation construction to manage complex regulatory requirements and deliver a facility that meets the operational demands of IAC’s growing aerospace services portfolio.

The Amarillo project consists of a nearly 80,000-square-foot aircraft hangar supported by a dedicated storage building and purpose-built support spaces. The hangar is designed to accommodate large aircraft while providing the environmental controls required for precision aerospace coating operations.

Key components of the facility include a standing seam metal roof system, shallow perimeter and spread footings, a full wet fire protection system, and a high-capacity air distribution system engineered to maintain consistent airflow throughout the hangar bay. The facility also incorporates an aircraft hangar door and multiple forklift drive-thru doors to support efficient material handling and aircraft movement.

Given the nature of IAC’s aerospace coating work, the facility includes multiple hazardous-use spaces requiring careful coordination during design and construction. Dedicated rooms are being constructed for hazardous paint mixing, hazardous paint storage, and hazardous wastewater treatment, each designed to meet stringent safety and environmental standards.

Mechanical and electrical systems are being tailored to support these operations, including controlled air changes within the hangar, oil-free compressed air infrastructure, and a centralized air receiver tank with multiple drops throughout the space. These systems are being integrated to ensure safe, efficient, and compliant operations without disrupting airport activities.

Construction is taking place within a secured, active airport environment, requiring close coordination with the Federal Aviation Administration (FAA), National Environmental Policy Act (NEPA) reviewers, Texas Aeronautics System (TAS) officials, and local authorities.

ARCO’s experience delivering aviation facilities across Texas is critical in managing overlapping agency requirements and ensuring full compliance without unnecessary delays.

The project site presents multiple challenges, including utility conflicts within restricted airport boundaries and multiple utility easements requiring both city and airport approval. Challenging soil conditions further complicate site development, requiring strategic management and reuse of existing soils.

ARCO is responding by re-sequencing construction activities to avoid schedule impacts, resolving utility conflicts within secured airport limits, and coordinating closely with airport operations to maintain access and security. These efforts allow the project team to address obstacles efficiently while keeping the overall project on track.

ARCO’s early involvement as a design-builder allows for the development of several cost-saving design alternatives and accurate cost control from the start. For example, ARCO proposed a design alternative reducing electrical service requirements from 3,000 amps to 2,000 amps while maintaining operational capacity. ARCO is also utilizing existing crushed concrete and site fill to reduce material import costs and improve sustainability.

Additionally, long-lead materials were released during early phases to lock in pricing and avoid schedule impacts, and the wastewater system design was simplified to improve constructability and long-term efficiency. These measures are delivering meaningful savings while preserving the integrity of the facility’s specialized systems.

To optimize the overall project schedule, ARCO developed multiple design and sequencing strategies to maximize efficiency and avoid potential delays throughout construction. ARCO is advancing design, permitting, and procurement activities in parallel rather than sequentially. Grading and pad preparation have been re-sequenced to regain lost time caused by unforeseen conditions, and agency reviews are being overlapped wherever possible to avoid approval delays.

Pre-engineered metal building components are being staged strategically, allowing erection to begin immediately upon delivery. This proactive approach enables ARCO to sustain momentum and meet project milestones despite evolving conditions.

• Delivering a complex aircraft hangar within an active, secured airport environment

• Maintaining strong cost and schedule control under evolving scope conditions

• Achieving full compliance with FAA, NEPA, TAS, and local requirements

• Supporting advanced aerospace coating operations through specialized facility design

• Collaborating closely with International Aerospace Coatings throughout the project