MAAS Aviation Dual Bay Hangar

Mobile, Alabama

Delivering a dual bay hangar with advanced structural systems and LEED Gold certification

Project Overview

JESCO served as the design-build contractor for a Dual Bay Hangar expansion for MAAS Aviation on the Airbus campus in Mobile, Alabama. The project included full infrastructure site work with utility connections and an aircraft apron tied into the existing taxi lane. The hangar itself is a 150-foot clear span, steel-framed structure with a minimum 31-foot ceiling height over the fuselage and wings, rising to nearly 48 feet at the tail section. Features include two-leaf, motor-operated bi-parting hangar doors with a motorized RSST coiling tail door, as well as energy-efficient exterior materials such as insulated metal wall panels and a mechanically fastened TPO roofing system. Designed to meet the highest environmental standards, the project is targeting LEED Gold Certification by the U.S. Green Building Council (USGBC).

1.5 million SF distribution facility

Floor storage (430,000 SF) & Rack storage (450,000 SF) Employee Amenities Advanced logistics capabilities

Employee Amenities

Advanced logistics capabilities

93,000 SF Dual Bay Paint Hangar

Motor-operated, bi-parting hangar doors with an advanced RSST coiling tail door system

150-foot clear span structural steel hangar with ceiling heights up to 48 feet

LEED Gold Certification by the U.S. Green Building Council (USGBC)

Data Point - Callout - Brief Summary

Project Duration

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Project Duration: 18 months

Project Scope

Components

Two 10-Leaf Motor operated around-the-corner bi-parting hangar doors
150’-0” Clear span, structural steel framing building
Administrative offices and mechanical space
Solberg RF3
Employee lockers
Down draft mechanical exhaust system
LEED Gold Certification by the U.S. Green Building Council (USGBC)

This distribution center significantly enhances Mercedes-Benz’s parts logistics network in North America, combining high-volume storage, precision inventory management, and efficient loading/unloading systems in a single, fully integrated facility.

Impact

Challenges and Solutions

Constructing a large-span, specialized aircraft facility required careful structural planning and integration of advanced MEP systems. JESCO ensured the hangar’s clear-span steel trusses, ventilation tunnels, and safety systems met the operational and regulatory needs for aircraft painting while maintaining worker safety and workflow efficiency.

Challenges
& Solution

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Challenges

Solution

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Principal at FSB

Airbus A220 Hangar 31

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