BZI Steel – Project Spotlight
Engineered to accommodate oversized access requirements, the BZI Steel clear-span facility was delivered by Western Steel Buildings and features a 72′ × 20′6″ sidewall opening to support heavy fabrication operations.
Project Spotlight
Patey Aviation Hangar
Custom Multi-Hangar Aviation Complex
Patey Aviation partnered with Western Steel Buildings to create a 67,000 sq. ft. aviation complex designed for private aircraft operations, premium storage, and integrated support spaces. Western Steel engineered a signature L-shaped multi-hangar configuration, combining a large 180′ × 100′ primary hangar with five additional 70′ × 80′ hangars—each optimized for efficient aircraft movement and operational flow.
The campus also includes several amenity buildings that provide office, lounge, and support functions, all integrated seamlessly with the hangar structures. Featuring standing seam roofing, durable steel wall systems, and clear-span interiors, this project demonstrates Western Steel’s ability to deliver high-performance aviation environments tailored for long-term reliability and functional precision.
Project Scope & Scale
- Use: Private aviation hangar complex with integrated office and support facilities
- Total Building Size: 67,000 sq. ft.
- Primary Hangar: 180′ × 100′
- Secondary Hangars: Five hangars, each 70′ × 80′
- Amenity Buildings: Multiple attached support buildings featuring architectural wall systems
- Frame Type: Tapered clear-span steel frame system
- Roof Types: Symmetrical gable (hangars) and single-slope (amenity buildings)
- Roof Panels: Standing Seam, 24-gauge, SMP/Galvalume
- Wall Panels: R-PBR panels with architectural T-Groove accents on amenity buildings
- Insulation: 6″ R-19 roof and wall insulation for hangars
Key Challenges
- Coordinating a multi-hangar aviation campus that functions cohesively as a single operational system.
- Ensuring seamless aircraft access and circulation across hangars of different sizes.
- Integrating amenity structures without disrupting hangar operations or design continuity.
- Maintaining a unified architectural appearance across varied building types.
Solution / Approach
- Engineered a custom L-shaped layout designed around efficient aircraft movement and storage needs.
- Delivered clear-span hangar interiors to maximize usable floor area and aircraft capacity.
- Applied standing seam roofing for long-term performance and clean architectural lines.
- Integrated office and support buildings using architectural panel systems for visual cohesion.
- Structured the complex to allow long-term flexibility and future operational enhancements.
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Unique Features
- Signature L-shaped aviation campus totaling 67,000 sq. ft.
- One 180′ × 100′ primary hangar paired with five 70′ × 80′ hangars.
- Multiple integrated amenity buildings with architectural finishes.
- Clear-span structural design enabling efficient aircraft operations.
- Standing seam roof system with low 0.5:12 slope for aviation-grade performance.
Building Specifications
Primary Hangar (Building A)
- Size: 180′ × 100′
- Eave Height: 33′-9″
- Roof Type: Gable, 0.5:12 slope
- Roof Panels: Standing Seam, 24-gauge
- Wall Panels: R-PBR, 26-gauge
- Insulation: 6″ R-19
Secondary Hangars (Building B)
- Size: Each 70′ × 80′
- Eave Height: 30′
- Roof Type: Gable, 0.5:12 slope
- Roof Panels: Standing Seam, 24-gauge
- Wall Panels: R-PBR, 26-gauge
- Insulation: 6″ R-19
Amenity Buildings (1–6)
- Use: Office, lounge, storage, and support functions
- Sizes: 18′–25′ wide × various lengths
- Wall Panels: Architectural T-Groove systems
- Roof Type: Single-slope, 0.5:12
- Roof Panels: Standing Seam
Sustainability / Compliance
- Standing seam roof enhances energy efficiency and weather resilience.
- R-19 insulated envelope supports stable interior temperatures.
- Steel construction provides long-term durability and reduced maintenance.
- Engineered to meet aviation facility standards and structural codes.
Results & Benefits
- Delivered a large-scale aviation campus designed for operational precision and long-term reliability.
- Maximized aircraft capacity through clear-span hangar design.
- Created a cohesive architectural environment across multiple integrated structures.
- Provided a durable, low-maintenance aviation facility built for long-term performance.
Build an aviation facility engineered for performance, capacity, and long-term value.
Western Steel Buildings is SolutionCentric.®
We started Western Steel to create solutions to the major challenges of our industry. Western Steel Buildings is SolutionCentric.® Client problem solving is at the core of what we do. Every day, our team looks for the opportunity to proactively help projects go right.
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