27m (w) x 24m (l) x 6.5m (h) Commercial Aircraft Hangar, Cessnock NSW

Hunter Valley Hangars approached Techspan Building Systems to design, engineer and manufacture a brand new commercial aircraft hangar for a site at Cessnock airport in New South Wales.

The Brief

The client had a few specific requirements including a 6 metre office and amenities building, precast concrete fire separation wall between the office and main hangar to meet building codes, structural support for a large on roof solar system and an automated door solution that would enable direct access to the airport runway, maximum accessibility/clearance for their aircraft and remote operation.

Project Overview


Commercial Aircraft Hangar


Hunter Valley Hangars


Cessnock NSW

Project Features

Size & Structure

27m (w) x 24m (l) x 6.5m (h)


  • Structural Steel Frame
  • Precast Concrete
  • Architectural Cladding


  • 20m wide x 6m high hydraulic tilt door with remote operation and complete weather seal
  • 6m office and ammenities area with architectural cladding
  • Precast concrete fire separation wall between office and main hangar area
  • Engineered roof to support large solar system
  • Fire exit doors to building code
  • Insulation
  • Roller door to front of hangar

Our Innovative Solution

Drawing on over 25 years experience in custom aircraft hangars, the team at Techspan tailored the design, engineering and manufacture to this 27m wide x 24m long x 6.5m high facility to suit the exact needs of their client.

The main structure of the building consisted of a structural steel frame including 27m roof spans that required no centre column support – maximising the usable floor area and aircraft accessibility.

The additional structural engineering on the roof allowed for our client to mount a very large solar power panel system – this system combined with a backup generator allows for this facility to be completely self sufficient when it comes to energy needs.

The door solution delivered is extremely impressive, incorporating a 20m wide x 6m high hydraulic tilting door system with superior sealing to minimise weather, dust or debris ingress. It also features an integrated sensor that halts the door operation if it detects any obstructions with it opening or closing axis. It is also fully remote operable, allowing the aircraft pilots to approach the hangar and gain access to there hangar by simply pressing a button on the remote control.

Architectural cladding to the front office facade and colourbond cladding to the main hangar structure was chosen to compliment one another and achieve a clean, modern and professional looking facility.

Techspan were extremely proud to support Hunter Valley Hangars to achieve a positive outcome for their new Cessnock Airport facility – Manufactured to Australian standards. Designed for purpose. Engineered to perform.

Proof of yet another Techspan project ‘Structured to Work’.

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If you’re looking to increase the operational efficiency of your business with a new purpose built solution, the TechSpan team can help! Get started with a free design consultation to start planning a building structured to work for your needs.

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