1. Runway to Opportunity – Why Hangars Matter Now
2. Demand Drivers Developers Can’t Ignore
3. Pre-Construction & Planning Checklist
4. Key Design Features to Get Right
5. Revenue Models & ROI
6. Case Insight – Ascent Aviation Services Hangar Expansion, Marana AZ
7. Conclusion
Worldwide demand for aircraft hangars is projected to climb from about $1.15 billion in 2024 to nearly $1.9 billion by 2032 (6.4 % CAGR) —evidence that air-side real estate is becoming one of the most resilient niches in commercial construction. Driving that growth is a simple supply-and-demand gap: there are more planes (and soon, more drones) than sheltered bays. The General Aviation Manufacturers Association reported 764 business-jet deliveries in 2024, up 4.7 % year-over-year, while the FAA Aerospace Forecast (FY 2024–2044) projects the U.S. turbine-aircraft fleet will expand another ≈ 2 % annually through 2044.
Entrepreneurs and developers have taken notice. In Texas, a luxury aircraft hangar condo lists for $460 per ft² shell (Airspace Texas), while progressive FBO operators are redesigning footprints to accommodate eVTOL fleet staging and high-amp battery charging. For commercial-real-estate sponsors, understanding which construction method—pre-engineered metal building (PEMB), site-built steel, or concrete tilt-up—reaches cost parity at various square-footages is critical to winning deals before a competitor’s crane shows up on the apron.
Before pouring a slab, developers need to know why hangar demand is spiking. Business-jet departures sit about 33 % above Pre-Covid levels. Meanwhile, an AOPA survey of airport managers found 71 % of U.S. GA airports keep wait-lists for hangar space. Add eVTOL prototypes racing toward 2027 certification and newly built Sun-Belt hangar-condo shells listing at ≈ $460 / ft² — e.g. a 3,250-sf unit at Addison (KADS) offered for $1.495 M on Airspace Texas — and the shortage comes into sharp focus. The 3 demand drivers below show why projects that align footprint, electrification, and fire-life-safety with next-generation aircraft have a clear runway for growth.
Together, these trends point to a durable, undersupplied market—rewarding sponsors who deliver hangars sized, powered, and protected for tomorrow’s aircraft.
Before you commit to dirt work or steel orders, the real key to a successful hangar project lies in thorough pre-construction planning. This is when you validate market demand, pinpoint the right site, secure financing, and nail down regulatory approvals—so that once shovels hit the ground, you’re executing a proven, bankable plan. Treat this checklist as your pre-flight briefing: cover each item now, and you’ll clear the runway for on-time delivery, on-budget performance, and a hangar that tenants can’t wait to occupy.
Before you dive into drawings and bids, it’s essential to put in the groundwork that makes—or breaks—a hangar project. This planning phase isn’t about selecting doors or panels just yet; it’s about validating the market, locking down your site, lining up financing, and charting a clear path through permits and approvals. Treat this as your blueprint for success: cover these steps now, and you’ll save time, money, and headaches once construction begins.
Cover these steps before breaking ground, and you’ll be executing a hangar project that meets market needs, secures financing, navigates red tape efficiently, and delivers strong returns.
Before you lock in your hangar’s footprint, think about the day-to-day needs of the pilots, technicians, and tenants who will use it—and the regulations you’ll face down the road. Getting these 5 design basics right up front saves headaches, keeps operating costs in check, and makes your hangar a standout in the marketplace.
Wide-opening doors (up to 140 ft) with dependable lift systems ensure smooth entry for jets, drones, and support vehicles—no waiting or bottlenecks.
A robust interior slab and reinforced apron stand up to tug tractors, forklifts, and heavy aircraft traffic without cracking or settling.
A modern foam or water-deluge suppression setup meets today’s NFPA standards and avoids costly retrofits when regulations tighten.
Insulated wall panels and reflective roofing substantially cut heating and cooling needs—keeping tenants comfortable and utility bills down.
High-capacity electrical service (think 480 V, megawatt-class charging) ensures your hangar can support eVTOLs, electric ground gear, or other next-gen aircraft.
By focusing on access, durability, safety, efficiency, and future-proof power, you’ll create a hangar that draws premium tenants, minimizes maintenance, and stands the test of time.
Before breaking ground on a hangar project, it’s crucial to understand the different ways you can monetize the space—and what kind of returns each model typically delivers. Whether you’re selling individual condos, locking in a long-term FBO tenant, or combining lease income with maintenance-and-repair services, each approach carries its own upfront investment and cash-flow profile. The table below summarizes the three dominant revenue models and their expected IRRs.
| Model | Upfront CapEx | Revenue Stream | Typical Unlevered IRR |
| Hangar Condo Sales | High (shell + basic finish) | One-time sale + ongoing HOA fees | 13–16 % (Marcus & Millichap, Industrial Market Overview 2024) |
| FBO Long-Term Lease | Medium (custom core + shell) | 20-year triple-net rent | 9–11 % (CBRE US Investor Intentions Survey 2025) |
| Hybrid Lease + MRO | High (includes MRO fit-out) | Lease income + maintenance-service fees | 12–14 % (Aviation Week, Hangar Economics Report 2024) |
Tip: Adding specialized fit-outs—like paint booths or dedicated battery-charging rooms—can command rent premiums of $2–$4 / ft².
Choosing the right mix depends on your capital constraints, desired cash-flow profile, and operational appetite. With clear expectations around costs and returns, you’ll be positioned to select the model that best aligns with your investment goals and market demand.
Ascent Aviation Services broke ground at Pinal Air Park in March 2024 on two new wide-body aircraft hangars—adding 180,000 SF of hangar space plus 60,000 SF of storage and shop area—to serve Boeing 777-300ER conversion lines for Israel Aerospace Industries. With a $55 M capital investment, the expansion is expected to generate over 300 new aviation jobs and bolster Ascent’s MRO capabilities on the U.S. West Coast ascentmro.com.
| Metric | Result |
| Total Hangar Space | 180,000 SF of new hangar capacity + 60,000 SF of support/shop space |
| Structure | Pre-engineered steel framing with tilt-up concrete end walls |
| Doors | Dual 120 ft bi-fold doors for each bay |
| Schedule | 18-month design-to-completion timeline, first aircraft in-house by Q4 2025 |
| Capital Investment | $55 million (~$306 / ft² for hangar shell) |
| Workforce Impact | Creates 300+ new jobs at Marana MRO facility |
Lessons for Developers
This example illustrates how large-scale MRO hangars can be delivered efficiently by leveraging pre-engineered systems alongside conventional concrete—and how early stakeholder engagement can accelerate approvals and labor mobilization.
Hangars are no longer just airplane garages; they’re multi‑purpose revenue engines serving charter fleets, drone operators, and eVTOL vertiports. Whether the optimal solution is a nimble 80 K SF PEMB or a 220 K SF tilt‑up fortress, cost clarity and schedule certainty remain non‑negotiable. SCB Construction Group brings the experience, supplier muscle, and design‑to‑fab precision to deliver both.
Ready to explore your next hangar project? Book a 30‑minute feasibility consult and discover why builders, developers, and airport executives across the Southeast trust SCB Construction Group.
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