What are the common structural forms of aircraft hangars?

Aircraft hangars are special large-span steel structure buildings. The main design challenges are the ultra-large column-free clearance, structural stability, and resistance to wind and snow. There are three main types of hangar structures on the market: portal frame, bolted ball structure, and tubular truss. These three types differ significantly in their load-bearing principles, span capacity, cost, and applicable scenarios, which are also the main basis for hangar scheme selection, budget control, and construction implementation (design should follow local standards, such as EU Eurocode, US IBC, etc., specific local standards prevail).

1. Portal Frame Structure

Structural Principle: A portal frame is a rigidly connected steel column and beam structure forming an integral portal frame, belonging to a planar load-bearing structure. The load is directly transferred to the steel columns and foundation through the roof steel beams. The system is simple, the force transmission is clear, and it is the most mature lightweight steel structure system.

Main Advantages: High degree of component standardization, simple processing, fast construction, and short cycle; low overall cost and less initial investment; convenient on-site installation, and low difficulty in later maintenance, rust removal, repair, and renovation; suitable for low-cost construction of simple hangars.

Main Disadvantages: Significant limitations in planar stress; steel consumption increases significantly with ultra-large spans, reducing economic efficiency; relatively weak overall structural rigidity, limiting wind, snow, and earthquake resistance; relatively significant roof deformation, unsuitable for heavy-load roofs and extreme climate areas (wind and snow loads according to EN 1991, earthquake resistance according to EN 1998, etc., specific requirements depend on the project site).

Applicable Span: Conventional applicable span: 10–30 meters; cost-effectiveness and stability decrease significantly beyond 30 meters.

Suitable Projects: Primarily used for simple hangars with small to medium spans, low loads, and no major maintenance requirements, such as helicopter hangars, small general aviation aircraft hangars, simple business jet parking garages, and small parking sheds for flight training centers.

2. Bolted Ball Structure

Structural Principle: The bolted ball structure is a three-dimensional spatial force-bearing system composed of multiple members interlocked at grid nodes. Loads are evenly distributed in multiple directions, with no single concentrated stress area, resulting in coordinated overall load-bearing and completely overcoming the span limitations of planar structures.

Main Advantages: High overall stiffness, strong integrity, good resistance to deformation, and good seismic, wind, and snow resistance; allows for ultra-large column-free clear spans of up to 100 meters, with complete and unobstructed internal space; controllable steel consumption and high cost-effectiveness even with ultra-large spans; the roof can bear equipment and maintenance loads, suitable for high-standard maintenance operations (steel structure according to EN 1993, etc., specific requirements may vary depending on the project site).

Main Disadvantages: A large number of members, resulting in greater processing and assembly workload than portal frames; high installation accuracy requirements, with strict control over the quality of node bolts or welding, otherwise affecting the overall load-bearing capacity; compared to tubular trusses, the building's lines appear denser.

Applicable Span: Standard applicable span: 40–120 meters, a core selection for large-span hangars.

Suitable Projects:Widely used in civil aviation passenger aircraft overhaul hangars, multi-stand continuous hangars, large transport aircraft hangars, and professional maintenance hangars in high-altitude, snowy areas. It is a commonly used structural form for large-scale standardized aviation hangars (export projects must be designed according to local specifications).

3. Tube Truss Structure:

Structural Principle:Tube trusses are formed by intersecting and welding round and square tube profiles, combining planar trusses into an overall spatial structure. Members are primarily subjected to axial tension and compression, resulting in clear force transmission and high material utilization. It belongs to a lightweight, large-span structural system.

Main Advantages: Lightweight structure with strong span capacity; efficient force distribution and steel saving; simple member arrangement, clear lines, and a modern, grand appearance, with a higher aesthetic appeal than space frames; highly malleable design, allowing for curved, arched, and other irregular roof shapes, suitable for landmark buildings; minimal interior obstruction and spacious interior.

Main disadvantages: The intersecting welding process requires high precision, resulting in higher processing costs than portal frames; the overall structural integrity and resistance to extreme loads are slightly inferior to bolted ball structures, and stability is slightly weaker under heavy loads and extremely harsh conditions (export projects generally require ISO 3834, EN 1090, etc. certifications, subject to local project requirements).

Applicable span: Typical applicable span: 50–100 meters, suitable for ultra-large span high-end hangars.

Suitable projects: Primarily used in airport landmark hangars, high-end business jet bases, general aviation demonstration hangars, irregularly shaped aviation buildings, and ultra-large span single-position high-end maintenance hangars, balancing structural performance and architectural aesthetics.

Comprehensive comparison of the three hangar structural forms:

(1) Span capacity comparison: Portal frame < Pipe truss ≈ Bolted ball structure. Portal frames are only suitable for small to medium spans, while bolted ball structures and pipe trusses can meet the needs of ultra-large column-free hangars. (2) Structural Stability Comparison: Bolted Sphere Structure > Tubular Truss Structure > Portal Frame. The bolted sphere structure offers superior three-dimensional synergistic stress distribution, resulting in better resistance to wind, snow, earthquakes, and deformation, making it suitable for harsh working conditions.

(3) Aesthetics and Transparency Comparison: Tubular Truss Structure > Portal Frame > Bolted Sphere Structure. Tubular trusses offer clean, transparent lines and a superior architectural feel, making them suitable for exhibition-style and landmark hangars.

(4) Cost-Effectiveness Comparison: Portal frames are more cost-effective for small to medium spans, while bolted sphere structures offer high cost-effectiveness for very large spans. For high-end projects, tubular trusses are preferred (the cost of tubular trusses is typically 2–3 times that of portal frames, subject to actual costs).

(5) Summary of Main Applicable Scenarios: Portal frames are suitable for small, simple parking hangars; bolted sphere structures are suitable for large, heavy-duty, and high-safety-standard maintenance hangars; tubular trusses are suitable for high-end hangars with attractive aesthetics, unique shapes, and very large spans. Conclusion When selecting an aircraft hangar structure, there's no need to pursue a single "best" structure. The key is to match the project's span, function, budget, and site conditions. Clearly defining the stress characteristics and compatibility boundaries of portal frames, bolted ball structures, and tubular trusses allows for a better balance between construction costs and building quality, while ensuring hangar safety and stability and meeting aircraft parking and maintenance needs.

Frequently Asked Questions (FAQ)

Q1: Which structure is most cost-effective for small hangars? 

A: For simple hangars with a span of less than 30 meters and only intended for parking, portal frames are preferred due to their low cost, fast construction, and simple maintenance. Bolted ball structures should be considered for maintenance or larger spans.

Q2: What structural considerations are necessary for export hangar projects?

 A: The design should primarily adhere to local project specifications, such as EU Eurocode (steel structures EN 1993, wind resistance EN 1991, earthquake resistance EN 1998) and US IBC/AISC 360, with specific requirements depending on the project site. Pipe truss welding generally also requires ISO 3834 and EN 1090 certification.

Q3: How to choose between bolted ball structures and pipe trusses? 

A: If stability, heavy-load maintenance, and performance in harsh weather are prioritized, choose bolted ball structures; if aesthetics, unique shapes, and a sense of openness are valued, choose pipe trusses. Both have similar long-span capabilities; the main differences lie in appearance and performance under extreme conditions.

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