The COVID-19 pandemic initially caused turbulence for the aviation industry, but the sector is soaring once again with a surge in commercial and private travel, resulting in increased demand for infrastructure, including aircraft hangar construction utilizing lightweight, durable, and thermally efficient insulated metal panels (IMPs).

“The industry is booming back so quickly now, and people are flying airplanes so much that they are coming into maintenance faster than they were before, especially because there was pent-up demand during COVID,” Frank Stevens, Embraer Aircraft vice president for global MRO centers, told Aviation Week.

Aviation MRO and FBO Businesses Need Aircraft Hangar Space

Aviation maintenance, repair, and overhaul (MRO) operations and airport fixed-based operators (FBO), both require hangar space to do business and are driving forces behind an aircraft hangar global market projected to grow from $6.2 billion in 2022 to $8.3 billion by 2030.

In some areas of the U.S., new aircraft hangar construction can not take place fast enough with the Embraer Aircraft maintenance facility in Nashville sold out through 2024, and room for only one to two more aircraft at its Macon, Georgia facility.

Aviation International News (AIN) reported in March 2023 a shortage of hangar space among the top 200 or so airports frequented by business aviation passengers. The publication said the problem is not new to the industry but has become more acute for several reasons:

• The majority of demand is focused on large markets where people want to travel such as Miami, Dallas, and Los Angeles.
  
  
• The move towards remote work, and longer travel stays, has also expanded the need for space at smaller locations such as Bozeman, Montana.
  
  
• Business jets and other aircraft stay in service longer, requiring more maintenance time.
  
  
• New aircraft are being brought into the market with 712 business jets delivered worldwide last year, including 400-plus in the U.S. market, requiring millions of new square space in aircraft hangars.
  
  
• Aircraft are getting larger, requiring more space, with the largest aircraft in the Bombardier line (Challenger 604) in 1996 requiring 4,485 sq. ft. Today, Bombardier’s Global 7500 requires 11,648 sq. ft.
  
  
• Aircraft hangar footprints are soaring to new heights with hangars built 30 to 40 years ago having a clearance of 24 feet or less, but today’s taller jets require 28-foot high doors.

Milo Zonka, vice president of real estate with Florida-based FBO operator and hangar developer Sheltair, told AIN that in the Los Angeles area alone, companies have added more than half a million square feet of hangar space over the past several years, all of which is now fully occupied.

“I think you can say demand is definitely outstripping supply in the major metropolitan areas, and then in the secondary markets, there might be a little bit of capacity, just not the right capacity, the 28-foot-high doors,” Zonka told AIN. “We’re full in every location and it’s a mad dance in South Florida, for example. It’s a daily search for aircraft that are either new to the owner or the owner is relocating.”

IMPs: Durable, Lightweight, Thermally Efficient Aviation Market Solution

Insulated metal panels (IMPs), panels that consist of two metal sheets – interior and exterior corrosion-resistant steel facings bonded to a core material, which is typically made of foam insulation -- are a popular construction material in the aviation industry because they are strong, lightweight, and thermally efficient.

IMPs are commonly used for the walls and roofs of aircraft hangars, as they can be quickly and easily installed.

The panels are prefabricated to the desired size, and then simply bolted or clipped into place on the building's steel frame. This reduces the time and labor required for construction and can result in significant cost savings.

IMPs also offer excellent fire resistance and durability, which are critical considerations in aviation facilities.

The metal outer layers are resistant to fire and can withstand heavy wind loads and other extreme weather conditions. This makes IMPs a reliable and safe choice for aircraft hangars, especially in areas such as Florida and Texas.

IMPs Create Climate-Controlled Environment for Aviation

In addition to their ease of installation and weather resistance, IMPs foam insulation core provides excellent thermal insulation, which helps to keep aircraft hangar interiors at a stable temperature.

This is important for protecting aircraft and other equipment from damage caused by extreme temperature fluctuations. Aircraft storage and maintenance operations require work to be done in climate-controlled environments for several reasons:

• Protection from temperature and humidity: Extreme temperatures and humidity can damage aircraft components, particularly those made of composite materials. Temperature changes can cause expansion and contraction of materials, leading to stress on the structure. High humidity can lead to corrosion and deterioration of electrical systems. A climate-controlled environment helps to maintain a stable temperature and humidity level, protecting the aircraft from these issues.
• Safety and comfort of workers: Working on aircraft in extreme temperatures can be dangerous and uncomfortable for workers. A climate-controlled environment provides a safe and comfortable workspace, allowing workers to focus on their tasks without distraction.
• Compliance with regulations: Many aircraft maintenance tasks require strict environmental controls to be in place, to comply with regulations and ensure the safety and airworthiness of the aircraft. Climate-controlled environments help to meet these requirements, reducing the risk of regulatory violations and potential safety issues.
• Improved quality of work: Aircraft maintenance requires precise measurements and alignments, and any changes in temperature or humidity can affect the accuracy of these tasks. A climate-controlled environment helps to maintain consistent conditions, ensuring high-quality work is completed.

U.S., North America Dominate Aviation Infrastructure Needs

The U.S. not only has the most airports worldwide with some 13,513 as of 2022, but that number is equal to the combined number of airports in the next 10 largest markets.

Overall, North America accounts for almost half of the world’s 40,000+ airports, and along with that a great demand for aircraft hangar space and other infrastructure.

In addition to new hangar construction, look for contractors to take advantage of IMPs in other ways in the aviation market including:

• Aviation Retrofit: Larger aircraft hangars are needed to accommodate the growing size of commercial and private jets so there will be growth over the next decade in aviation retrofit construction.
• Terminal Construction and Retrofit: The growing appeal of IMPs in architecturally based applications with color and design choices make them aesthetically appealing for customer-facing projects such as new terminal construction and retrofits of aging aviation terminals.

Contact Green Span Profiles today to learn more about our high-quality, made-in-America insulated panels that can help aviation businesses protect their important assets.