Infrastructure development at airports supports both efficient and safe air transportation. Both airport operators and airlines rely upon dedicated buildings that facilitate the maintenance, inspection, and repair of aircraft. Of all of these types of buildings, hangars have always been among the most critical structures in terms of maintenance, repair, and overhaul (MRO) processes.
Hangar construction is a combination of architectural engineering, facility operation planning, and regulatory compliance. As both aircraft fleets continue to grow, as does the technological sophistication of aircraft, so too will the need for aviation infrastructure to develop to meet new demands and to facilitate increasingly complex maintenance functions.
Role of Hangars in Aviation Maintenance
All commercial airline flights must meet specific international regulations developed by organizations such as the FAA (Federal Aviation Administration), EASA (European Aviation Safety Agency), etc. The intent behind these regulations is to ensure that all commercial aircraft remain compliant with industry-wide safety standards throughout the entire lifecycle of each respective aircraft.
Hangars create a sheltered environment where all maintenance activity can take place. A hangar protects aircraft from inclement weather; it allows technicians to inspect, repair, test aircraft systems and complete routine maintenance on aircraft. Routine maintenance activities completed within a hangar include structural inspections, engine services, avionics testing, routine maintenance schedules, etc.
Well-planned maintenance hangar support maintenance activity in two ways: first, sufficient space to perform various activities is provided; second, the flow of technicians, tools, and equipment is facilitated via adequate lighting and planned workflow. Technicians must be able to freely access components on an aircraft therefore, large unobstructed interior spaces with no internal obstructions (columns, beams, etc.) must be created during design.
Structural Engineering Considerations
As aircraft hangars are required to span greater widths than many other building types, they are classified as large-span structures. Therefore, many large-span hangars must accommodate wide-body aircraft requiring interior spans up to 200 feet. To achieve such expansive open interior spaces engineers utilize advanced structural solutions including: steel trusses, space frames, and modular structural systems. The purpose of utilizing these structural systems is to provide a stable structure while maintaining large amounts of clear floor space free of obstructive elements (support columns).
Hangar doors present another significant design consideration. Hangar doors must be capable of opening wide enough to accommodate the largest diameter aircraft that will enter/exit the hangar while providing reliability and ease-of-use. Commonly utilized solutions include sliding doors, vertical lift doors and fabric door systems.
Companies specializing in the development of structural systems for use in aviation facilities include Spantech. These companies specialize in developing structural systems to meet the above-mentioned requirements for aviation facilities.
Operational Efficiency in Hangar Design
In addition to addressing structural aspects, hangar designers must consider how efficiently maintenance personnel can conduct maintenance operations. All MRO activity involves numerous technicians performing simultaneous work on individual aircraft systems. A well-designed building facilitates smooth movement of technicians, tools and equipment.
Typically, maintenance zones are segregated based on activity type. For example, separate areas may be designated for storing parts and supplies related to inspection and repair activities. By segregating these areas into specific zones the time spent coordinating between technician teams is minimized, thereby improving overall efficiency in maintenance operations.
Another aspect of design that significantly contributes to improving operational efficiency in hangar design is lighting systems. In order for technicians to properly inspect aircraft components and systems adequate light must be provided over a substantial area. Due to its ability to produce consistent light output at reduced power consumption, LED lighting has emerged as a preferred option when designing lighting systems for aircraft hangars.
Ventilation/Air Circulation Systems:
To improve working conditions and minimize exposure of technicians to harmful substances (fumes from fuel/solvent/maintenance materials) ventilation/air circulation systems were incorporated into hangar design. Additionally, ventilation/air circulation systems help remove potentially hazardous fumes generated by fuel burning engines or other potential ignition sources.
Safety Standards in Hangar Design:
Hangar construction must adhere to very stringent safety standards. One major concern associated with hangar construction is fire protection systems due to the potential presence of flammable materials (aviation fuels). Most modern hangars employ foam-based fire suppression systems designed specifically for aviation applications.
Additionally, emergency access routes, evacuation planning/hazard management systems are included in the design of the building. These features enable technicians to safely conduct their work within larger and more complex hangars.
Regulatory Environmental Factors:
Hangar design must also satisfy environmental regulations. Waste disposal practices/fuel storage methods/noise reduction techniques must be implemented in accordance with local/national/international regulations.
Future Advances in Hangar Infrastructure:
Development within the aviation industry is ongoing as airlines begin introducing new aircraft models and expanding their global fleets. These changes directly affect the design of MRO facilities.
Newer aircraft contain innovative materials/digital systems/new diagnostics tools that enable technicians to analyze flight performance information about the aircraft being serviced. Hangars must be designed to support these emerging inspection tools and digital maintenance systems that allow technicians to assess an aircraft’s condition using flight performance data.
Finally, sustainability is becoming a more prominent factor when considering future plans for aviation infrastructure. Examples of sustainable options being considered include: energy-efficient HVAC/building envelope/systems/renewable energy options. Airport/Service providers investing in this type of infrastructure can ultimately lower operational expenses while supporting continued expansion of global air transportation capabilities.
