Tinker AFB Multi-Bay Hangar
A maintenance complex is built to support diverse aircraft fleets, delivering scale, safety and long-term reliability for sustained readiness in a secure, high demand environment.
Project
Overview
At Tinker Air Force Base in Oklahoma, a massive aircraft maintenance hangar was developed to support the newly formed Air Force Sustainment Center and its mission to maintain readiness across a diverse and demanding fleet.
Designed and supplied by Butler Heavy Structures, the facility delivers the scale, performance and assurance required for long-term depot-level maintenance in a secure military environment.
The project consists of a massive multi-bay hangar complex engineered to accommodate multiple wide-body and legacy aircraft platforms under one roof.
The primary structure is a two-bay hangar measuring 444 feet wide by 196 feet deep, complete with two 44-foot-deep nose docks and a clear door opening spanning 428 feet. The structure supports a five-part vertical lift fabric door system, providing 65 feet of clear height for aircraft tail sections and 49 feet of clearance to the mullions above the wings. This configuration allows aircraft to move efficiently while maintaining strict operational clearances.
Adjacent to the multi-bay structure is a single-bay hangar measuring 239 feet wide by approximately 230 feet deep. A 218-foot-wide by 65-foot-high tail opening accommodates an additional door system, extending the facility’s flexibility and aircraft capacity.
Together, the hangars are configured to house up to two KC-46A tankers within the multi-bay and an additional tanker in the single-bay space.
Fire separation and life safety were integral to the design. The two hangars are divided by a 4-inch ThermalSafe® fire-resistant insulated panel wall, providing compartmentalization without sacrificing operational flow.
Within the hangar volume, a two-story office structure adds approximately 6,850 square feet of second-floor space, integrating administration directly into the maintenance environment while maintaining clear sightlines and secure separation.
The roof system is a standing seam metal roof engineered to meet FM 1-90 criteria for wind resistance and long-term durability.
Exterior walls are clad with 2-inch CF-42 insulated sandwich panels in two custom colors, delivering thermal performance, protection and visual consistency across the complex. The facility achieved LEED® Silver certification, reflecting a commitment to efficiency and responsible design within a high-performance military installation.
The hangar supports programmed depot maintenance for a broad range of aircraft, including KC-135s, E-3s, B-52s, B-1Bs and Airbus A330s. Interior spaces include open training rooms, conference rooms, a technical order library, utility rooms and extensive support spaces.
Every aspect of the facility was engineered to support readiness, safety and long-term performance. The result is a mission critical maintenance hub built to endure, ensuring aircraft availability and operational confidence for decades to come.
