Design & Fabrication, Unloading, Door Installation, Electrical Installation, Owner Training
To support the next generation of business aviation maintenance, a newly constructed 175,000-square-foot aircraft maintenance complex was designed to serve operators across North and South America and beyond. The facility is capable of accommodating all current Falcon aircraft models—including the ultra-long-range Falcon 10X—and is configured to perform major maintenance, inspections, and aircraft modifications on up to 18 aircraft simultaneously.
A critical component of the building’s functionality was the need for unobstructed, wide-span access on both sides of the structure. AeroDoor was selected to manufacture, install, and commission a door system capable of meeting the project’s operational, structural, and environmental demands.
The pre-engineered metal building features two opposing aircraft openings, each measuring 355 feet wide by 30 feet high. This configuration improves aircraft flow, reduces towing complexity, and increases overall efficiency within the maintenance environment.
Each opening is served by a three leaf horizontal rolling steel door system. Individual door panels measure 118 feet wide by 30 feet tall, enabling the massive openings to be segmented while still providing 2/3 access at any one time.
Given the site’s exposure and a 150 mph wind design zone, the door system was engineered to accommodate significant structural movement without compromising performance. The AeroDoor system allows for 15 inches of controlled vertical deflection, ensuring a secure door during high-wind events while protecting both the door structure and the building envelope.
This level of movement tolerance is especially critical for wide-span hangar doors integrated into pre-engineered metal buildings, where building deflection must be anticipated and accommodated in the door design.
The door system is powered by AeroDoors internal motor assemblies supplied by AeroDoor and fed via an overhead trolley bus system, eliminating the need for draped cables which can interference with hangar operations.
Push-button control stations are provided on the interior or exterior of each door leaf for convenience and operational flexibility. Each leaf can be operated independently by a single person, allowing maintenance teams to open only the portions of the hangar required for a specific aircraft movement—improving energy efficiency and reducing cycle times.
Integrated walk door openings within the door system provide safe and convenient pedestrian access without requiring the movement of the main door leaves.
AeroDoor’s involvement extended across the entire lifecycle of the door system. The company was responsible for:
By maintaining control over every phase of the process, AeroDoor ensured that the final installation aligned precisely with the building structure, operational requirements, and long-term maintenance expectations of the facility.
As aircraft continue to grow in size and complexity, maintenance facilities must be designed with equal foresight. This project demonstrates how properly engineered large-span hangar door systems play a critical role in enabling modern aviation operations—balancing structural performance, ease of use, and reliability in demanding environments.
For facilities supporting high-value aircraft and high-throughput operations, door systems are not simply building components—they are mission-critical infrastructure. AeroDoor’s contribution to this project reflects its ongoing commitment to delivering engineered solutions for the world’s most demanding aviation facilities.
2770 Dillard Rd, Eustis, FL 32726
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(866) 226-3667
AeroDoor International is a manufacturer, installer and service company of steel sliding aircraft hangar doors. AeroDoor products are proudly produced in the United States of America.
