Steel Aircraft Hangar Construction: A Complete Guide to Custom Private Jet Hangars

When it comes to protecting your aircraft investment, whether a personal private jet or a corporate fleet, choosing the right hangar is mission-critical. A custom steel aircraft hangar delivers unmatched strength, efficiency, and long-term value, while providing a versatile aviation space tailored to your specific needs. At APX Construction Group, we specialize in designing and building premium pre-engineered metal building (PEMB) hangars that meet aviation standards and exceed owner expectations.

What Is a Steel Aircraft Hangar?

A steel aircraft hangar is a large freestanding structure designed specifically for housing, protecting, and maintaining aircraft. These hangars are typically constructed using pre-engineered steel framing systems, which allow for wide, clear-span interiors, essential for maneuvering planes, equipment, and maintenance activities without interior support obstructions.

Steel hangars support a range of aviation facilities, from small single-aircraft storage to expansive corporate jet hangars with integrated workshops, offices, and lounge space.

Why Choose Steel for Your Hangar?

Steel has become the preferred material for aircraft hangars across the aviation industry due to its many structural and economic advantages:

1. Exceptional Strength and Durability

Steel offers a high strength-to-weight ratio, providing a solid structure that can withstand weather extremes, including heavy snow loads, strong winds, and hail, while maintaining its structural integrity.

Unlike wood or lighter materials, steel resists:

• Rot, pests, and decay
• Warping and shrinkage
• Fire and corrosion (with proper treatments)

This longevity translates into decades of reliable performance with minimal maintenance.

2. Clear Span Interiors

Steel framing enables clear-span construction, resulting in a large, unobstructed interior space without columns. This is crucial for aircraft hangars, where every foot of unobstructed floor space improves aircraft access, maneuverability, and functionality.

3. Faster Construction and Predictable Costs

Pre-engineered steel systems are manufactured off-site with precision, reducing on-site labor, weather delays, and construction time. This efficiency helps keep budgets predictable and projects on track.

4. Customization and Flexibility

Steel aircraft hangars are easily customizable. From door systems and interior layouts to insulation, mezzanines, and office spaces, steel structures can be tailored to match precise operational needs and aesthetic vision.

5. Long-Term Value

Lower maintenance costs, resistance to environmental wear, and structural resilience make steel hangars a smart investment. The strength and adaptability of steel protect your aviation assets and support future expansion if needed.

Key Design Considerations for Your Private Jet Hangar

Designing an aircraft hangar involves more than just building walls and a roof, it requires precision engineering, regulatory compliance, and thoughtful planning.

1. Aircraft Size and Clearances

Your hangar design must accommodate:

• Wingspan
• Tail height
• Required turn radius

Private jets — such as light, mid-size, or heavy jets — carry different canopy and access requirements. Structural design must allow for safe taxiing and movement within the hangar.

2. Clear Span and Structural Loads

Steel framing systems are engineered to handle clear-span loads without interior columns; however, regional wind, snow, and seismic considerations must be factored into the structural design.

3. Hangar Doors

Hangar doors are one of the most important functional and budgetary components:

• Sliding doors offer simplicity and reliability
• Bi-fold doors provide quick open/close cycles
• Hydraulic doors deliver high performance for large openings

The choice depends on aircraft type, frequency of use, and operational preferences.

4. Interior Layout and Amenities

Interior planning should balance function and comfort:

• Dedicated maintenance bays
• Storage for tools and equipment
• Office and administrative spaces
• Pilot lounges or crew areas
• Climate-controlled storage and environmental controls

5. Regulatory Compliance

Aircraft hangars must comply with local building codes and aviation authority regulations. If constructing near airport property, approvals such as FAA Form 7460-1 may be required.

6. Expansion and Future-proofing

Planning for future aircraft upgrades or increased fleet size now can save time and cost later. Design flexibility enables your hangar to evolve with your evolving aviation needs.

Cost Considerations: What to Expect

Building a custom steel aircraft hangar is a significant investment, and understanding the cost drivers helps you plan effectively.

1. Size and Footprint

Hangar cost scales with size. Larger hangars require more steel framing, wider doors, additional foundation work, and increased utilities.

2. Steel Materials

Steel can account for 40–50% of the total project cost, encompassing framing, panels, roofing, and corrosion protection. Markets and supply chains can influence pricing.

3. Site Preparation and Foundations

Aircraft-rated concrete floors with reinforcement are essential for safe operations. Your site may also require grading, drainage systems, and taxiway connections — all of which affect total cost.

4. Doors and Specialized Equipment

Hangar doors vary widely in price, depending on their size, type, and level of automation. Fully electrified or hydraulic systems command a premium.

5. Climate Control and Insulation

If your hangar stores high-value aircraft or serves as a maintenance space, HVAC and insulation significantly boost comfort and asset protection — but add to upfront costs.

6. Amenities and Interior Spaces

Offices, lounges, bathrooms, and break rooms introduce additional construction elements, including electrical, plumbing, and finishes.

Planning Your Aircraft Hangar Project

Embarking on a steel aircraft hangar project requires a structured process to ensure success:

1. Initial Consultation and Needs Assessment

Begin with a professional evaluation of your aircraft, operational requirements, and long-term objectives. What types of aircraft will be stored? Will adjacent workspace or offices be needed?

2. Site Evaluation and Permitting

Your construction partner assesses soil conditions, zoning requirements, and runway access and determines the necessary permitting needs. This early work informs engineering and budgeting.

3. Engineering and Design

Engineers produce structural plans that take into account region-specific code compliance, wind and snow loads, and clear span requirements.

4. Construction and Project Management

Experienced builders coordinate site prep, steel erection, door installation, HVAC, and finishes — ensuring safety and quality at every stage.

Why Partner With APX Construction Group

At APX Construction Group, we bring decades of experience in aviation and PEMB construction to deliver high-performance steel aircraft hangars, custom-built to your vision and standards. Here’s why aircraft owners trust us:

✔ Proven Expertise in Hangar Construction

We’ve partnered with private owners, airport authorities, and commercial operators throughout the region, delivering hangars that meet strict aviation requirements with precision and efficiency.

✔ Customized Solutions for Every Requirement

From basic aircraft storage to fully equipped private jet facilities, complete with offices and amenities, we tailor our designs to suit your operational needs and budget.

✔ Collaborative, Client-Focused Approach

You’re involved in every step — from initial concept to project completion — ensuring your hangar delivers the performance, appearance, and functionality you expect.

✔ Commitment to Quality and Safety

We adhere to the highest construction standards and safety practices, ensuring your hangar is built to last and complies with applicable building codes and aviation regulations.

✔ Regional Reach With Local Understanding

Based in Mankato, Minnesota, and serving clients across Minnesota and beyond, APX Construction Group has the regional expertise to navigate local permitting and site challenges.

Conclusion: Building Your Steel Aircraft Hangar With Confidence

A steel aircraft hangar is more than a storage facility — it’s a strategic investment in your aviation operations, safety, and peace of mind. With steel’s durability, design flexibility, and long-term performance, you gain a facility built to protect your aircraft and optimize your workflow.

Whether you’re storing a single private jet or managing a fleet, APX Construction Group has the expertise to bring your steel hangar project to life. From design to delivery, we partner with you to create a functional, beautiful aviation space that reflects your standards and exceeds expectations.

Ready to protect your aviation investment? Contact APX Construction Group today to discuss your steel aircraft hangar project and discover how we can make your vision soar.