Heliflite Hangar

Heliflite required a new hangar at Ardmore Airport that could accommodate a private jet with a 23-metre wingspan while presenting a refined, contemporary presence within the airfield environment.

The project came with clear constraints. Boundary limits restricted building width, the exposed site demanded enhanced wind and seismic performance, and ground investigations revealed peat beneath the surface, making traditional heavy tilt-panel construction unsuitable. A lighter, more considered structural approach was needed to maintain performance without increasing foundation risk.

Formsteel engineered and constructed the structural solution using its SuperSpan™ 440 beam system. The high-strength beam configuration enabled a 23-metre clear internal span with slimline columns, maximising usable space without breaching site limits. Instead of conventional tilt-panels, a lightweight structural stud wall system was introduced to reduce foundation loads while maintaining fire and performance compliance.

Structural members were also integrated into the oversized tilt door assembly, ensuring the door could withstand significant wind pressures without compromising function. Through coordinated modelling, fabrication, and installation, Formsteel delivered its scope in just three months, using approximately 47% less steel than a traditional structural solution.

The result is a high-performance aviation facility that balances strength, efficiency, and architectural clarity.