Aircraft Hangar Construction in Denver, Colorado

Wingspan drives every dimension of an aircraft hangar, starting with the door. A corporate jet, a regional airliner and a helicopter fleet each need a different clear opening, door height and floor depth, and the structure that spans the door opening can be the largest steel member on the job. Before any drawing is made we ask what aircraft will sit inside, now and in ten years, because the answer sets the clear span, the door type and the foundation loads.

Denver International Airport gives the metro a scale of aviation that most cities lack. DEN owns 33,531 acres (52.4 square miles) and has six runways, five at 12,000 feet and one at 16,000 feet, the longest public-use runway in North America. It set a passenger record of 82,427,962 in 2025, and its Operation 2045 plan proposes four new concourses with about 100 more gates by 2045. Growth of that kind brings charter operators, maintenance providers, ground-handling companies and corporate flight departments to the area, and they all need covered space.

We build aircraft hangars and the aviation support buildings around them: maintenance shops, parts stores, ground equipment storage and offices. Our high-bay crane-ready building experience carries into the work, since a hangar is a high-bay structure with a very large door opening and a specialized fire protection system.

Clear span, door selection and the airfield environment

The clear span is the first design decision. A single-aircraft hangar for a business jet is a different structure from a multi-bay maintenance hangar, and the decision between a clear-span frame and a frame with interior columns affects how aircraft can be positioned. Large spans use steel trusses or deep plate girders, and sometimes a pre-engineered system, which is why our pre-engineered metal building practice is relevant to smaller hangars.

Door selection is equally important. Bifold doors, hydraulic doors, sliding doors and fabric doors each have different costs, speeds, clearances and maintenance profiles. The door header carries the roof load across a wide opening, so the door and structure are engineered together. The airfield environment adds its own constraints: construction cranes can penetrate protected airspace, materials must be kept clear of taxiways, and vehicle access is controlled. We coordinate with the airport operator from the outset.

Structure, floor and the systems that make it a hangar

A hangar floor is a heavy slab, designed for aircraft wheel loads, jacking loads and the occasional fuel or hydraulic fluid spill. It is sloped to trench drains that lead to oil-water separators, and it is finished with a sealer or coating that makes cleanup possible. Foundations carry the door loads and the wind uplift on a building with a large, open face, so they are heavier than those of a similar warehouse.

Utilities include high-capacity electrical service, compressed air, shop power, lighting and the specialized fire protection described below. Hangars with maintenance functions add overhead cranes or monorails, hydraulic lifts, exhaust extraction and heating. We coordinate these systems into the building so that a mechanic can work in the space without extension cords, and so that a future crane can be added without rebuilding the roof. Site work includes the apron connection, ramp pavement, fuel access, security fencing and a fire water loop and hydrant system, in line with the airport's standards.

Airspace review, fire code and the building permit

Construction at or near an airport brings an airspace review before a building permit. The FAA reviews proposed structures and cranes for their effect on navigable airspace, using a notice filing that must be submitted well before work begins. We prepare this early, because a determination that requires a lower building height or a different crane position affects the design.

The building itself is reviewed by the jurisdiction. Denver adopted new building and fire codes on June 13, 2025 based on the 2024 International Building Code, with a transition period of about six months during which the 2022 or 2025 Denver Building Code could be used. Hangar fire protection follows the model code and recognized standards, and it commonly uses foam-water sprinklers or high-expansion foam in larger hangars. We bring the fire protection engineer into design, and we confirm requirements with the fire marshal before the structure is finalized.

Working on an active airfield

Safety on an airfield is stricter than on an ordinary site. Workers need airport badging, vehicle operators need training on movement areas, and equipment must have flags and lights as required. Foreign object debris is a real hazard: a loose bolt or a scrap of banding on a taxiway can damage an engine. Every crew on site holds daily sweeps and control materials accordingly.

Hot work in a hangar and around fuel requires special controls. Welding, cutting and grinding near fuel-handling areas or inside an existing hangar require permits, fire watches and gas testing. If we build next to an operating hangar, we protect aircraft from dust and debris and coordinate noisy work with the operator's schedule. Our project teams carry that discipline from site to site, and it also applies to the heavy lifts of long steel members.

What moves hangar cost

Cost depends on span, door and fire protection. A clear span doubled can more than double the structural steel, a large door can cost as much as a small building, and a foam fire protection system can add substantially to the mechanical budget. Climate also matters; in Denver, hail and snow loads on a very long roof need attention, and Denver ranks 10th among U.S. areas of at least 50,000 people for hailstorm risk. Owners should consider roof and door impact resistance, since hail damage to aircraft parked outside is one reason operators build.

Land and access are the other drivers. A greenfield site such as the airport-area parcel bounded by Tower Road, Himalaya Road and 70th and 72nd streets, covered by a May 16, 2022 amendment to Denver's Far Northeast Area Plan, has potential to become a local employment center, and a future hangar there would draw on new roads and utilities. An advanced manufacturing or aerospace user might combine a hangar with production space, much like the buildings described under manufacturing plants. For airside parcels, a lease with the airport shapes cost and schedule as much as construction does. See also the Denver International Airport area and Commerce City, which is directly adjacent to the airport.

Tell us the aircraft

Send the aircraft types, the site and the intended use and we will return a clear span, a door recommendation and a schedule that includes the airspace review. We can also price a hangar and support building together.

Common Questions

What size hangar do I need for a mid-size business jet?

It depends on the aircraft, but door width, door height and floor depth must clear the wingspan and tail with a safe margin on each side. We use the manufacturer's published dimensions and plan for the next aircraft you are likely to buy. Building slightly larger at the start costs less than replacing a door later.

How long does FAA review take?

It varies, and we do not promise dates. The airspace review needs to be filed early, and the determination can affect building height or crane use. We file during design and track it as a milestone.

Can hangars be heated efficiently in Denver winters?

Yes, with radiant floor or tube heaters, insulated doors and zoned controls. Large doors are the main source of heat loss, so door choice and seals matter. We design heating for the use: storage hangars need less than maintenance hangars.

Do you build on airport property?

We can build on airport land under a ground lease, following the airport operator's design standards, security rules and approvals. The lease terms, utility connections and access routes should be understood before design is finalized.

What fire protection does a hangar require?

Requirements depend on the size, the use and whether aircraft are fueled inside. Foam-water sprinklers and high-expansion foam are common in larger hangars. We confirm the requirement with the fire marshal before the structure is final.

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