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BETTESWORTHConstruction
aircraft hangar design

How EMPAD Designs Aircraft Hangars, Car Washes and Automotive Facilities

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EMPAD Architecture + Design treats aviation and automotive buildings as operational machines as much as architectural statements. Its work runs from schematic design through construction completion and includes aircraft hangars, luxury vehicle storage, car washes, service centers and indoor motorsport venues. The firm’s own portfolio and a 2026 Metal Architecture feature show how each building type demands a different response to span, circulation, climate, maintenance and customer experience.

What aviation and automotive architecture involves

These projects are commercial facilities organized around the movement, storage or servicing of machines. An aircraft hangar must provide unobstructed volume for an aircraft and its tug, large openings for access, maintenance support and weather protection. A car wash is a tightly sequenced process building: vehicles enter, queue, pass through a wash tunnel and leave without conflicting movements. A vehicle-storage condominium adds climate control, owner amenities and private circulation. A service center combines repair bays with reception, parts handling and customer areas. An indoor speedway must fit a track, spectator and event functions inside a safe, legible plan.

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EMPAD says its aviation and automotive services cover schematic design through construction completion. Its aviation and automotive portfolio identifies SheltAir and Sarasota hangars, Express Car Wash, Tesla Service Center projects, Woodie’s Wash Shack, Paddock 1 Storage and Autobahn Indoor Speedway and Events. These examples indicate the breadth of the practice; the dimensions and completion dates below are project descriptions from EMPAD, not industry averages.

EMPAD portfolio: project types and stated figures

Project or building type Location or coverage EMPAD-stated size and status Primary architectural problem
Paddock 1 Storage Tampa, Florida 80,000 square feet; completed 2023 Climate-controlled luxury vehicle storage, outdoor pathways and spaces where owners can gather
SheltAir hangars Multiple Florida locations 50,000 square feet; completed 2023 Aircraft storage and maintenance with clear-span movement and large access doors
Woodie’s Wash Shack Florida locations 3,000–6,000 square feet; date not stated. A described two-story model has a 100-foot wash tunnel High-throughput wash operations expressed through a recognizable customer-facing form
Tesla Service Centers Florida, Tennessee and Indiana 40,000 square feet; portfolio listing includes renovation and new-construction work; date not stated Service-bay planning, customer arrival and branded entrance elements
Autobahn Indoor Speedway and Events Florida locations 60,000–90,000 square feet; date not stated Indoor track, event, lounge and circulation requirements
Sheltair project at Tampa International Airport Tampa, Florida 50,000 square feet (4,645.15 square metres); reported September 29, 2026 Wide-span hangar volume, tug access, daylight and hurricane-related design requirements
Medallion Homes private hangar Sarasota, Florida 30,000 square feet (2,787.1 square metres); described as ongoing in the September 29, 2026 report Private-hangar volume combined with a more articulated office and arrival zone

Because these figures come from individual project listings, they should be used to understand EMPAD’s range rather than to estimate a typical hangar, wash or service-center size.

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How hangar design solves span, access and weather demands

Clear span and aircraft movement

The first question in a hangar is not appearance; it is whether the building can accommodate the aircraft, its turning envelope and the tug or other equipment used to move it. Columns that interrupt this path can make an otherwise large building unusable. EMPAD’s portfolio describes hangar work around aircraft storage and maintenance, efficiency, resilience and expansive bay doors that support access and maneuverability.

In the 2026 Metal Architecture feature, EMPAD president and principal architect Chris Culbertson says, “a PEMB is the most common, cost-effective way to get the span that you need for a hangar.” A pre-engineered metal building (PEMB) is therefore a structural strategy for achieving the required open bay; it is not a guarantee of a particular price or performance on every site.

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Sheltair at Tampa International Airport

The reported 50,000-square-foot Sheltair project uses PBR steel roof and wall panels. False parapets screen rooftop mechanical equipment, while translucent panels bring controlled daylight into the otherwise deep volume. Two office sections sit around an open area that permits aircraft-tug access. The feature also describes the design in relation to Florida hurricane-resistance requirements. Specific engineering calculations, product ratings and code approvals are not provided, so those should be confirmed in the project’s construction documents rather than inferred from the material description.

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Doors, apron and internal logistics

Hangar planning has to connect the interior bay to the apron or taxi-side approach. Door width and height, threshold details, approach geometry and the location of offices or maintenance support all affect whether an aircraft can enter without repeated repositioning. EMPAD’s description of open tug-access areas illustrates why circulation is planned before partitions and finishes. A developer should establish the aircraft list, wingspan, tail height, turning radius, tug dimensions and maintenance activities during programming.

Private hangar expression

The Medallion Homes project in Sarasota is described as an ongoing 30,000-square-foot private hangar in the September 29, 2026 report. Its office area combines aluminum composite material panels with vertically and horizontally oriented ribbed panels. That combination shows how a large utilitarian volume can receive a distinct arrival and office identity without changing the basic need for a clear aircraft bay.

Why car-wash architecture is different

Process first, building second

A wash facility is organized around a continuous sequence: site entry, queueing, payment or membership processing, wash equipment, drying, exit and any vacuum or detailing functions. The tunnel length, vehicle stacking and turning paths determine the plan more directly than a conventional retail frontage would. EMPAD lists Woodie’s Wash Shack locations at 3,000 to 6,000 square feet and describes a two-story model with a 100-foot wash tunnel.

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Brand language translated into materials

EMPAD’s Woodie’s Wash Shack description uses wood and stone, vivid colors and retro signage inspired by 1960s surf culture. The architecture makes a repetitive operational building recognizable from the road while retaining a straightforward wash sequence.

Personal Pitstop Express: from sketch to buildable form

For Personal Pitstop Express in Tampa, the client asked for a “streamlined and sleek and modern” building. Culbertson recalls, “His words were ‘streamlined and sleek and modern.’ Architecturally, that language speaks metal.” The team began with a rough sketch, translated it into SketchUp and presented the client with two additional schemes that were simpler and less costly.

The selected concept used light-gauge steel framing. Corrugated metal panels followed the building’s angled geometry, producing changing shadow patterns as daylight moved across the facade. The project demonstrates a practical decision point: an expressive form can be developed, priced and compared against simpler alternatives before the client commits, but the more complex geometry may carry added structural, detailing and fabrication work.

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Automotive facilities combine storage, service and experience

Paddock 1 Storage

EMPAD describes Paddock 1 Storage in Tampa as new construction completed in 2023, with 80,000 square feet. The firm says it designed the luxury garage condominium in its entirety, including climate-controlled indoor space and outdoor pathways. Its program is therefore broader than a warehouse: vehicles need controlled storage, while owners need a comfortable way to arrive, move through the property and spend time there.

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Service centers

The Tesla Service Center portfolio listing covers renovations and new construction in Florida, Tennessee and Indiana, with a stated size of 40,000 square feet. A service-center plan typically has to separate customer arrival from vehicle circulation, provide efficient service-bay access and accommodate staff, parts and waiting functions. EMPAD’s reported material approach includes aluminum composite material (ACM) at some entrances or towers. Culbertson explains, “We use ACM quite a lot on entrance features, usually. It’s not typically the entire building. It’ll be an entrance feature or a tower.” This is an architectural accent strategy, not a claim that ACM forms every service-center envelope.

Lakewood Ranch car condominium

The 2026 feature describes a Lakewood Ranch car condominium with steel framing, a primarily concrete facade, ACM and horizontal metal accents. A metal pergola is designed to resemble wood. Culbertson says of that pergola, “It’s going to last forever with its longevity, no maintenance, and no fading.” That is his promotional assessment; it should not be treated as an independently verified service-life or maintenance study. Material selection still needs project-specific review of coatings, connections, corrosion exposure, cleaning and replacement access.

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Comparing the planning priorities

Facility Operational purpose Spatial priorities Reported structural or material strategy Experience and identity
Aircraft hangar Aircraft storage and maintenance Clear span, bay-door openings, apron connection and tug maneuvering Pre-engineered metal building systems; PBR steel panels; translucent daylight panels; screened rooftop equipment Efficient, resilient enclosure responsive to aircraft and weather
Car wash Vehicle throughput and washing Queue, tunnel length, circulation, equipment zones and exit operations Light-gauge framing and formed or corrugated metal cladding at the featured Tampa concept Retro surf expression at Woodie’s; sleek, angled metal expression at Personal Pitstop Express
Vehicle-storage condominium Protected storage and owner use Climate-controlled bays, private movement, outdoor paths and gathering areas Steel, concrete, ACM, horizontal metal accents and a metal pergola in the reported Lakewood Ranch example Hospitality and club-like owner experience
Service center Vehicle servicing and customer support Service bays, parts and staff circulation, customer arrival and waiting ACM used as an entrance feature or tower at some locations Recognizable arrival element without cladding the entire building in one material
Indoor speedway and events venue Indoor recreation, racing and events Track, spectator, lounge, event and life-safety circulation Specific assemblies not stated in the cited portfolio description Event-oriented destination with distinct public and participant zones

Materials: why the palette changes by building

EMPAD’s examples show no single “aviation” or “automotive” material package. The structural system follows span and loading; the envelope responds to weather, daylight and maintenance; and accents carry identity where customers arrive.

  • Pre-engineered steel: Used in the reported hangar approach to obtain a broad, economical span. Final member sizes, foundations, fire protection and corrosion protection remain project-specific.
  • PBR steel roof and wall panels: Specified in the Tampa International Airport Sheltair feature, with false parapets and translucent panels supporting a finished, daylit exterior and interior.
  • Light-gauge steel framing: Used for the selected Personal Pitstop Express form, allowing corrugated panels to follow angled geometry.
  • Corrugated metal cladding: Creates directional shadow and visual movement where panels track the car-wash form.
  • Aluminum composite material: Applied as an entrance feature or tower at some service centers and in the Medallion Homes hangar office composition, rather than assumed as a whole-building skin.
  • Concrete and metal accents: Combined in the reported Lakewood Ranch car condominium, including a metal pergola designed to look like wood.
  • Wood, stone, color and signage: Used in Woodie’s Wash Shack’s surf-inspired identity, demonstrating that operational efficiency and a strong visual theme can coexist.

A practical programming sequence for a new project

  1. Define the operating mission. State whether the facility stores, maintains, washes, services or hosts vehicles and aircraft. Include hours, staffing, throughput and event use where applicable.
  2. Map every vehicle movement. For aircraft, document the aircraft types, tug path, apron approach and door clearances. For cars, map entry, queue, service, wash, parking, vacuum and exit movements.
  3. Set the dimensional envelope. Establish clear height, span, door sizes, turning paths, tunnel length, bay depth and any future expansion zone before selecting a structural system.
  4. Separate public and operational circulation. Keep customers, owners, staff, maintenance crews, aircraft tugs and service vehicles from creating avoidable conflicts.
  5. Choose the structural and envelope strategy together. Compare a PEMB, conventional steel or light-gauge framing against the required span, geometry, fire strategy, weather exposure and budget.
  6. Plan daylight and mechanical screening. The Sheltair example uses translucent panels for controlled daylight and false parapets to screen HVAC equipment; similar choices should be tested against heat gain, maintenance access and local conditions.
  7. Develop identity at the right scale. Use cladding, ACM, signage, color or a tower to make the arrival legible without allowing an ornamental element to compromise doors, equipment access or drainage.
  8. Test alternatives before documentation. Personal Pitstop Express was modeled in SketchUp and shown with two simpler, lower-cost options. Presenting a preferred concept beside credible alternatives clarifies the cost of architectural complexity.
  9. Coordinate resilience and approvals. Florida projects must address demanding weather conditions; the Tampa hangar reporting specifically references hurricane-resistance requirements. Confirm current building-code, wind, flood, fire, aviation and environmental requirements with the project team and authorities having jurisdiction.
  10. Carry operations into construction completion. Verify door operation, drainage, equipment clearances, turning paths, lighting, wayfinding and maintenance access during commissioning rather than treating the building as finished when the exterior is complete.

What the EMPAD examples do—and do not—demonstrate

The portfolio demonstrates experience across unusually different facility briefs: a 50,000-square-foot hangar, an 80,000-square-foot vehicle-storage condominium, wash facilities as small as 3,000 square feet, 40,000-square-foot service centers and 60,000- to 90,000-square-foot indoor speedway venues. It also shows a design process that can move from a highly practical clear-span enclosure to a strongly shaped, client-tested car-wash form.

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Those project areas and material descriptions are not proof of universal cost savings, durability, energy performance or construction speed. The cited sources provide no industry-wide benchmarks or comparative test data. A developer evaluating a new facility should request project-specific structural calculations, code analyses, operating assumptions, lifecycle-cost work and maintenance requirements.

Product prices and availability are accurate as of the date/time indicated and are subject to change. Any price and availability information displayed on Amazon at the time of purchase will apply.

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