Wingnut Aviation

Wingnut Aviation required a permanent facility to house Sir Peter Jackson’s renowned collection of vintage aircraft. The brief extended beyond the requirements of a conventional hangar. The structure needed to accommodate 32 historic aircraft within a single uninterrupted space, while providing long-term durability, environmental protection, and architectural presence appropriate to the collection’s significance.

The structural demands were substantial. The design required a 50-metre clearspan without internal columns, a 39-metre-wide by 8-metre-high hangar door, and a 13-metre internal ceiling height. Located at Hood Aerodrome near a fault line, the building also needed to perform under seismic and wind loading conditions typical of exposed airfield environments.

Wingnut Aviation selected Formsteel to engineer and deliver the structural solution. The project marked the first implementation of the SuperSpan™ 650 beam system, enabling the required clearspan while significantly reducing structural weight and embodied carbon. The high-strength formed beams allowed modular transport and efficient installation using standard lifting equipment, reducing on-site complexity.

Concrete panels were integrated to meet fire-rating requirements, and structural members were coordinated with the oversized hangar door to maintain strength across the expansive opening. The main structure was erected in 11 days and completed in 16 weeks, saving approximately 40 days compared to conventional construction.

Approximately 47% less steel was used than a traditional structural solution, demonstrating how advanced beam engineering can deliver both structural scale and long-term preservation performance.