To support the 24-hour maintenance needs of a Colorado military aircraft hangar, WPSS engineered a Deluxe Industrial Shelving Deckover system. This shelf-supported solution maximized vertical capacity, providing thousands of square feet of secure storage for critical aircraft components without expanding the facility’s footprint.
The Challenge: Storing Thousands of Critical Aircraft Parts
A military aircraft hangar in Colorado faced a massive storage challenge. Providing 24-hour maintenance support for various military aircraft requires housing an incredible volume of parts—from massive fuel tanks, landing gear, and wheels to sensitive avionics and instruments.
Key Requirements:
- High Capacity: The solution needed to store thousands of SKUs of varying sizes and weights.
- Footprint Retention: The engineering team needed to increase storage capacity significantly without consuming additional floor space, which is critical for aircraft movement and maintenance operations.
- Safety & Security: Loose items needed to be contained to prevent injury to workers or damage to expensive components.
- Strict Compliance: As a government project, all structures had to meet or exceed rigorous OSHA, IBC, and seismic requirements.
The Solution: Deluxe Industrial Shelving Deckover System
Western Pacific Storage Solutions (WPSS) engineered a custom Deckover System using its high-capacity Deluxe Industrial Shelving.
Vertical Efficiency
Instead of a standard free-standing mezzanine, the team utilized a shelf-supported Deckover configuration.
- Dual-Level Storage: The design features Deluxe Industrial Shelving on the floor level supporting a deck and a second level of shelving above. This configuration provides maximum storage capacity with a minimum footprint.
- Heavy-Duty Support: Each shelf on the floor level was engineered to support 350 to 1,000 pounds, creating a robust foundation for the bulk storage platform above.
- Closed-Panel Design: To address safety concerns, the client chose closed-panel shelving . This design prevents items from falling through the back or sides, protecting both the inventory and the personnel working below.
Results: Rapid Deployment for Mission Readiness
The project was executed with military precision, moving from design to shipping in just 60 days.
| Outcome | Benefit to Client |
| Maximized Capacity | The Deckover provided thousands of new square feet of parts storage within the existing hangar footprint. |
| Operational Efficiency | A more organized and extensive parts inventory translates to less maintenance downtime, keeping aircraft mission-ready. |
| Safety Compliance | The structure met all critical government safety standards (OSHA, IBC, Seismic), ensuring a secure working environment. |
| Rapid Turnaround | The streamlined project took only 60 days to ship, ensuring the hangar could upgrade its capabilities quickly. |
By implementing a Deluxe Deckover, the military installation successfully optimized its logistics, ensuring that critical parts are always on hand to keep their aircraft flying. Ready to work on your next project? Big or small, WPSS has experts ready to assist! We provide layout guidance, spec sheets, and recommend best-practice clearances to ensure an efficient and space saving design. Contact us today for a quote.