When it comes to aviation facilities, the hangar is more than just a structure and storage. With aviation demand expected to remain strong in 2026, planning your next hangar now, no matter if you’re housing a single, small aircraft or managing a fleet, ensures you’ll be ready for the future.

If 2026 is the year you plan to build, here are three key considerations before you break ground:

1. Size: Small Aircraft vs. Fleet Needs

The footprint of your hangar is the first decision. Are you protecting a single-engine aircraft, or will you need room for multiple jets and support equipment?

• Small aircraft hangars often range from 40-60 feet wide and 30-40 feet deep.
• Fleet and commercial hangars require clear spans of 100-plus feet, specialized doors, and space for maintenance areas.

Planning for growth now can save significant costs later if your operations expand. For more details, check out this guide on Key Considerations for Choosing an Aircraft Hangar.

2. Efficiency: Build Speed and Energy Use

Once you’ve determined the right size, the next step is efficiency, both in construction and long-term operation.

• Prefabricated steel components allow faster assembly than traditional construction methods, minimizing downtime and reducing overall cost. Steel hangar construction continues to lead aviation projects thanks to speed, flexibility, and efficiency. Steel hangars go up faster than traditional buildings. This short video highlights how steel construction speeds up the building process.
• Energy efficiency can be enhanced with insulated wall and roof panels, natural daylighting systems, and strategic ventilation design.
• Butler® building solutions are engineered for sustainability and long-term durability, often lowering lifetime operating costs. As one of the nation’s top Butler® builder, we use these systems known for sustainability, strength, and proven performance. Here’s a closer look at one in action at one of our recent projects: Hangar and Fixed Base Operator Facility for Castle Aviation.

3. Location: Airport Partnership Needs

Finally, no hangar project succeeds without careful attention to site and airport partnerships. Building on or near an airport requires careful coordination. Before committing to a site, clarify:

• Ground lease requirements with the airport authority.
• Access to runways, taxiways, and fueling infrastructure.
• Zoning and permitting that may affect height restrictions or footprint size.

These factors influence both project cost and timeline. This video explains more about location and planning for aviation facilities.

Frequently Asked Questions

Q: What size hangar do I need for a small aircraft?

A: A single small aircraft hangar typically requires at least 40’ x 30’ to comfortably fit the plane, allow for wing clearance, and provide storage space for equipment.

Q: What makes a steel hangar more efficient than traditional construction?

A: Steel hangars offer faster build times, low maintenance, and open-span interiors without support columns. Here’s a quick breakdown of why steel hangars are built for efficiency.

Q: What makes Butler® buildings different?

A: Butler Manufacturing™ has led the industry for more than a century. As a Butler® builder, Freeman Building Systems leverages proprietary engineering, roof systems, and energy-efficient design to deliver proven metal building solutions that last.

Flying Into the New Year

Planning a new hangar is a major investment, and one that pays off when done with the right partners. Freeman Building Systems has delivered aviation facilities across the region, from small aircraft hangars to full-service fixed base operator (FBO) buildings.

If 2026 is your year to build or expand a hangar, now is the time to start the conversation.

For over 30 years, Freeman Building Systems has been a trusted part of the community, delivering efficient and cost-effective design/build steel construction solutions. At Freeman, safety is woven into everything we do. From our rigorous on-site protocols to smart, safety-focused building designs, we are committed to delivering projects that stand the test of time without compromising the well-being of those who build and use them.