What is the right door system for my aircraft hangar?

When planning a new aircraft hangar in New Zealand, most owners choose either a sliding hangar door, a horizontal bi-fold, or a vertical bi-fold system - with sliding doors remaining the most common and cost-effective option for most projects. The right choice depends on your site conditions, how much clear space you have, local wind exposure, and how often you’ll open and close the doors.

When planning a new hangar, most people focus on the structure itself: making sure it is birdproof, vermin-proof, and free from internal braces that reduce space. But one of the most important decisions is often overlooked: choosing the right aircraft hangar door.

The door system you choose impacts not only cost but also functionality, maintenance, and how well your hangar performs in the long run. In this article, we cover the most commonly used aircraft hangar doors in New Zealand, their pros and cons, and which option may be best for your project.

Sliding doors

The sliding hangar door system is the most commonly used option, and for good reason. It is simple in design, low maintenance, and often the most cost-effective choice. These doors run on a bottom hangar door track set into the concrete floor, with a guide rail at the top. Recessing the track into the slab ensures a smooth entry and avoids the bump caused by tracks bolted on top of the floor.

Hangar sliding doors are versatile, working for openings of various sizes and shapes. However, they can be heavy to operate, and debris may collect in the recessed track, causing occasional jamming. You’ll also need to ensure there is adequate clear space along the sides of the building for the doors to slide past when fully open.

Horizontal bi-folding doors

Horizontal bi-folding aircraft hangar doors are often considered a premium option. Their main benefit is that the door panels fold neatly out of the way, requiring very little wall space for tracks or operating mechanisms.

Because the footings and framing generally need custom engineering, horizontal bi-folding doors typically come with a higher price tag. However, for those looking for a clean, space-efficient solution, they provide a high-quality result.

Vertical bi-folding doors

Less common but still effective, vertical bi-folding hangar doors are best suited to sites with limited side space where sliding hangar door tracks cannot extend past the building line. These doors can be partially opened, making them practical for sheds that house multiple smaller aircraft rather than one large plane.

The downside is that vertical systems often require internal guide tracks, which can reduce flexibility for storing equipment inside. They also include more moving parts, which means higher maintenance requirements compared to sliding systems.

High Wind Zone Considerations

Wind is a critical factor when choosing an aircraft hangar door system, as these structures often face high exposure. Weak connections between the door and the hangar frame can lead to damage during storms or strong gusts.

Buildings with structural steel and pre-dried timber provide stronger support for door systems compared to lighter roll form steel sheds, which may not hold fixings securely over time.

For high wind zones, sliding hangar doors are usually the most reliable choice. Panels can be designed smaller to reduce wind load, and heavier gauge steel frames and hangar door tracks can be used for added strength without significant extra cost.

Where to Source Hangar Doors

While some shed companies include basic doors with their kits, this may not provide the durability or precision needed for aircraft hangars. A better option is to work directly with a supplier or local engineer who specialises in aircraft hangar doors.

By fabricating frames, outriggers, rollers, and hardware locally, you ensure a precise fit, proper installation, and a tidy finish with no gaps for pests. This custom approach also allows you to choose the best system - whether it’s a sliding hangar door, horizontal bi-fold, or vertical bi-fold - for your specific site and aircraft needs.

Final Thoughts

Selecting the right aircraft hangar door comes down to more than cost. Consider site conditions, wind exposure, available space, and how often the doors will be used. Each system has unique benefits, but sliding hangar doors remain the most common in New Zealand due to their balance of affordability, reliability, and ease of use.

Our team has worked with clients across all three systems and can provide advice tailored to your project. If you are ready to start planning, complete our shed builder tool and outline your requirements. We’ll help you find the best solution so your hangar is built to last.