Boca Raton Executive Airport
Hangar Demolition

Demolition at an active airport like Boca Raton Executive Airport requires precise coordination before the first machine arrives on site. Our team worked with airport management to establish a secure perimeter that kept all operations within the project footprint. This ensured that dust, debris, and equipment movement did not interfere with neighboring hangars or active taxiways. Foreign Object Debris (FOD) is a constant concern in aviation environments, so we implemented a daily site sweeping protocol to ensure no loose material could migrate toward the runways or taxiways.

We mobilized two company-owned CAT 328 excavators to handle the primary structural work. Owning our fleet allows us to maintain a high production rate without relying on rented equipment that can fail or arrive late. At KBCT, we established clear haul routes for our trucks to minimize interaction with airport traffic, ensuring the project moved forward without causing delays to the facility's daily operations.

Safety and security are the priority on every commercial demolition project we take on. At KBCT, airport security required that crew members pass background checks before being cleared to work on the property. We maintained a designated point person on site at all times during active operations — responsible for coordinating with airport management, controlling crew access, and ensuring compliance with the facility's security protocols. This level of accountability is standard when working inside a secured aviation perimeter.

The hangar was a large-span steel structure with heavy-gauge metal roofing and walls. These buildings are designed to withstand significant wind loads, meaning the structural connections are reinforced and require high-capacity machinery to dismantle safely. We used the dual CAT 328 excavators to perform a controlled demolition, starting with the roof sections. By using two machines in coordination, our operators could stabilize the main steel trusses while cutting and removing the skin of the building. This method prevents the uncontrolled collapse of large structural members, which is critical when working in close proximity to other high-value aviation assets.

As the steel frame was exposed, we dismantled the structure in sections. Each piece was brought to ground level where it could be processed for hauling. Aircraft hangars often feature large-scale steel beams and tensioned cable systems that can be dangerous if handled by inexperienced crews. Our team used specialized attachments to shear the steel on-site, reducing it to manageable sizes for the haul trucks. The metal cladding and structural steel were separated immediately to streamline the recycling process.

Once the vertical structure was removed, the focus shifted to the reinforced concrete slab and the deep footers required for a building of this size. Aircraft hangars use high-strength concrete to support the weight of the planes and equipment, requiring heavy-duty hydraulic attachments to break up the material. Our excavators used hammers and buckets to pull the slab and extract the footings without damaging the surrounding asphalt or utilities.

For debris hauling, we deployed our fleet of Peterbilt dump trucks. These trucks handled the continuous cycle of loading and transporting material off-site to approved facilities. By running our own trucks, we control the schedule and ensure that material is never allowed to stockpile beyond our designated staging area. For projects with significant concrete volume, we can bring in our crushing and screening equipment to process material on site for reuse. For this project, the priority was rapid removal to meet the timeline for the next phase of development, so all debris was hauled off site.

Working in South Florida requires constant attention to dust control and environmental protection. During the hangar demolition, we used on-site water sources to keep dust levels to a minimum, ensuring that neither the airport operations nor the neighboring properties were impacted. This is particularly important when removing metal siding and roof sections that can create fine particles when sheared. We also monitored the weather daily, as high winds at the airport can quickly spread dust if not managed properly.

Logistics management also included the handling of specialized hangar systems. Older hangars can have complex electrical and mechanical systems that must be properly decommissioned. Our crew verified that all services were disconnected and safely removed before structural work began.