When planning a commercial aircraft hangar or Fixed-Base Operator (FBO) facility, standard general contracting often falls short. High-stakes aviation environments demand strict regulatory compliance (FAA, NFPA 409), massive clear-span engineering, and exact operational workflows.
At Freeman Building Systems, our design-build process eliminates the traditional friction between architects, engineers, and general contractors by delivering single-source accountability from initial layout to key turnover.
What Is the Timeline for Building a Commercial Steel Hangar?
The timeline to build a pre-engineered commercial steel hangar typically ranges from 8 to 14 months, depending on facility size, site utility complexity, and municipal permitting:
- Months 1–4 (Pre-Construction & Permitting): Site feasibility, FAA Part 77 clearance, Butler® engineering design, and local municipal approvals.
- Months 5–6 (Site Preparation & Foundation): Mass earthwork, utility infrastructure installation, and pouring engineered heavy footings.
- Months 7–9 (Steel Framing & Building Enclosure): Primary steel frame erection, MR-24® standing-seam roof placement, and insulated wall panel installation.
- Months 10–12+ (Interior Systems & Commissioning): High-capacity concrete slab placement, specialized hangar door fitting, NFPA 409 fire suppression, and final sign-off.
Phase 1: Pre-Construction, Engineering & Permitting (Months 1–4)
- FAA Part 77 Review: Navigating airspace clearance and height restriction evaluations.
- Structural PEMB Design: Engineering clear-span frames with Butler Manufacturing™ technology.
- Local Permitting: Coordinating zoning, environmental, and municipal approvals.
Phase 2: Site Development & Substructure (Months 5–6)
- Earthwork, mass grading, and utility infrastructure installation.
- Excavation and pouring of high-capacity structural footings to hold column loads.
Phase 3: Steel Erection & Building Envelope (Months 7–9)
- Assembly of primary rigid frames and secondary framing (purlins and girts).
- Installation of standing-seam roofs (such as the weather-tight Butler MR-24® system) and insulated wall panels (IMPs).
Phase 4: Systems Integration & Commissioning (Months 10–12+)
- Pouring specialized aircraft-rated concrete slabs designed for heavy wheel loads and Skydrol resistance.
- Installation of heavy-duty hangar doors (bottom-rolling, bi-fold, or hydraulic systems).
- NFPA 409 foam fire suppression, high-bay LED lighting, and MEP balance.
How Does the Freeman Building Systems Process Differ from Other Builders?
Most commercial construction delays occur because traditional design-bid-build models separate the architectural phase from the construction phase. Freeman Building Systems utilizes an integrated design-build approach coupled with an owner-operator mindset.
- Traditional Model: Client → Architect → Bid Stage → General Contractor (High friction, fragmented communication, budget surprises)
- Freeman Design-Build Model: Client ←→ Freeman Team (Single point of contact managing Design & Engineering, Butler Builder® Execution, and Municipal & FAA Coordination)
| Construction Metric | Traditional Design-Bid-Build | Freeman Building Systems Design-Build Process |
| Accountability | Split between architect and builder | Single-source project manager |
| Budget Accuracy | Known only after final bids are placed | Established early during conceptual design |
| Schedule Control | Prone to change-order delays | Accelerated by concurrent site prep and steel fabrication |
| Structural System | Conventional field-built structural steel | Precision Butler Builder® pre-engineered steel |
1. Owner-to-Owner Mindset
Freeman’s executive leadership team consists of owner-operators and an active pilot. We evaluate site planning, energy consumption, building codes, and operational flows through the eyes of facility owners who need predictability and long-term asset value.
2. Certified Butler Builder® Engineering
As a certified Butler Builder®, Freeman Building Systems leverages Butler® structural systems (such as Widespan™ framing). This delivers column-free interior space (up to 200+ feet), allowing aircraft to maneuver safely without risking tight-space structural impacts (“hangar rash”).
Case Study: Castle Aviation’s FBO & Hangar Expansion at CAK Airport
A contractor’s process strength is proven by long-term client trust. When Castle Aviation expanded operations at the Akron-Canton Airport (CAK), CEO Michael Grossmann selected Freeman Building Systems to execute both phases of their corporate expansion.
- Phase 1 Hangar (2018–2020): A 50,760 sq. ft. facility focused on aircraft maintenance, flight operations, and durable Butler® frame infrastructure.
- Phase 2 HQ & FBO Hangar (2024–2025): An 80,000 sq. ft. expansion featuring their Global Headquarters, an FBO passenger terminal, and 100-foot custom Aero International hangar doors.
The Project Challenge
Developing a combined corporate headquarters, maintenance hub, and FBO terminal requires solving complex operational criteria:
- Coordinating directly with Akron-Canton Airport authorities and municipal zoning boards.
- Installing massive custom hangar doors (100 ft wide by 28 ft tall) engineered for harsh Ohio winters.
- Integrating premium landside amenities (passenger lounges, pilot rest quarters, executive offices) alongside heavy airside industrial operations.
The Freeman Solution
- Phase 1 (50,760 sq. ft. Hangar): Delivered in 2020, featuring flexible maintenance bays and high-efficiency clear-span interiors.
- Phase 2 (80,000 sq. ft. Global HQ & FBO): Built with Butler MR-24® standing-seam roofing, specialized snow/ice drainage systems beneath door tracks, and fireproof steel doors equipped with fusible-link safety systems.
“Dan Freeman and his entire staff act like my friends along with being my builder. They are always there when I have questions or concerns… I couldn’t be happier to have the Freeman team be part of it.”
— Michael Grossmann, CEO/Founder, Castle Aviation
Frequently Asked Questions
What fire protection standard applies to aircraft hangars?
Aircraft hangars are governed primarily by NFPA 409 (Standard on Aircraft Hangars). Depending on the hangar group classification (Group I, II, III, or IV), requirements range from high-expansion foam deluge suppression systems to automatic water sprinklers.
Why choose a Butler® pre-engineered metal building over conventional steel?
Pre-engineered metal buildings (PEMBs) from Butler® are factory-engineered to precise specifications, reducing erection labor and jobsite waste. They offer larger clear-span capabilities without interior load-bearing columns and include factory-warranted standing-seam roof systems.
How does Freeman handle municipal airport zoning and FAA restrictions?
Freeman manages FAA Part 77 height evaluations, airport authority lease integration, site drainage, and local building code submissions as a standard part of our design-build pre-construction management.
Watch Behind the Build: Castle Aviation’s 80,000 Sq. Ft. Hangar & FBO for an in-depth look at how Freeman Building Systems collaborated with Castle Aviation to execute this state-of-the-art facility.
This video provides an authentic look at the design-build collaboration between Freeman Building Systems, Castle Aviation, and specialized suppliers during the construction of an 80,000-square-foot hangar facility at CAK Airport.
Behind the Build: Castle Aviation’s 80,000 Sq. Ft. Hangar & FBO
