Aviation construction is one of the most specialized sectors in the industry. Projects at airports and airfields carry unique requirements for airside access, security clearances, FAA coordination, and specialized systems that are not found on typical commercial construction projects. Estimating aviation work accurately requires knowledge of these requirements and their cost implications.

What Makes Aviation Construction Different

Airside Access and Security

Work within the secured perimeter of an airport requires background checks, security badges, and escort procedures for workers and vehicles. These requirements add cost to every phase of the project — from mobilization to daily operations — and must be reflected in the estimate.

FAA Coordination and Approvals

Construction near active runways, taxiways, and approach paths requires FAA coordination and approval. Construction Safety and Phasing Plans (CSPPs) must be prepared and approved before work begins. Temporary flight restrictions, runway closures, and nighttime work windows all affect the project schedule and cost.

Specialized Systems

Aviation facilities require specialized systems not found in typical commercial construction:

• Aircraft fueling systems — underground fuel storage, hydrant fueling systems, and fuel dispensing equipment
• Ground support equipment (GSE) power — 400 Hz power systems for aircraft ground power
• Aircraft rescue and firefighting (ARFF) — specialized fire suppression systems and equipment
• Airfield lighting — runway, taxiway, and approach lighting systems
• Navigational aids — ILS, VASI, PAPI, and other navigational systems

Pavement Design

Airfield pavements are designed to carry aircraft loads far exceeding those of typical highway or parking lot pavements. Concrete and asphalt pavement sections are significantly thicker, and the specifications for materials and construction are more stringent than standard highway specifications.

Types of Aviation Construction Projects

Terminal Buildings

Airport terminal construction involves all the standard commercial construction trades plus specialized systems for baggage handling, passenger boarding bridges, security screening, and concessions. Terminal projects are typically large, complex, and subject to strict operational constraints that affect the construction schedule.

Hangars

Aircraft hangars range from small general aviation hangars to large maintenance, repair, and overhaul (MRO) facilities. Key estimating considerations include:

• Clear span structure — large clear spans require heavy steel framing or specialized structural systems
• Hangar doors — hydraulic or electric bi-fold or sliding doors are major cost items
• Aircraft drainage — fuel and oil separator systems for floor drains
• Heating systems — radiant or forced air heating for large, high-bay spaces

Fixed Base Operators (FBOs)

FBO facilities include terminal buildings, fuel storage and dispensing systems, and aircraft parking aprons. These projects are typically smaller than commercial terminal projects but carry the same airside access and security requirements.

Airfield Pavement

Runway, taxiway, and apron pavement projects are civil construction projects with specialized pavement design requirements. The estimate includes earthwork, drainage, base course, and pavement — all designed to FAA standards.

Key Cost Drivers in Aviation Estimating

Security and access requirements — Background checks, badging, and escort procedures add cost to every phase of the project. Estimate these costs based on the number of workers and the duration of the project.

Nighttime and weekend work — Many airfield construction activities must be performed during low-traffic periods — nights, weekends, and holidays. Shift differentials and premium time add significant cost to the labor estimate.

Phasing and operational constraints — Aviation projects are typically phased to maintain airport operations during construction. Phasing adds cost through multiple mobilizations, temporary facilities, and the inefficiency of working in constrained areas.

Specialized equipment — Airfield construction requires specialized equipment — runway paving trains, airfield lighting installation equipment, and specialized testing equipment — that may not be available locally and must be mobilized from a distance.

Union Estimating provides aviation construction estimating services for general contractors and specialty subcontractors working on airport and airfield projects, with 48–72 hour turnaround on most projects.