WACO Aircraft Corp.

WACO Aircraft Corp.

Building a campus around growth

Expansion at WACO Aircraft Corporation was driven by more than production demand. It was about positioning the company for its next chapter, supporting a new aircraft line while creating an environment that reflects its legacy and craftsmanship.

The project brought together multiple functions into a single coordinated effort, including two large hangars, a fabrication shop and an engine assembly building. Each structure needed to perform independently while contributing to a larger campus designed for manufacturing, service and customer engagement.

Delivered in partnership with Pioneer Construction, a Varco Pruden™ Builder, the project required a level of coordination that extended beyond a typical single-building solution.

Executing multiple buildings at once

Rather than sequencing construction one building at a time, the team moved forward with four structures simultaneously. This approach accelerated delivery but required precise alignment across design, fabrication and construction.

Each building was designed to support a specific function within the operation. The hangars provide space for aircraft service and storage. The fabrication and engine buildings support production and assembly. Together, they create a workflow that connects each stage of the process.

This level of coordination ensured that the campus could begin operating as a complete system upon completion, rather than as a series of disconnected facilities.

Integrating for performance and efficiency

Across all buildings, the structural and envelope systems were selected to support durability, efficiency and long-term performance.

The ThermoDeck™ roof system provides a clean interior finish while supporting structural performance and thermal efficiency. Paired with the ThermaClad™ wall system, the building envelope delivers consistent performance across each structure, helping maintain interior conditions while reducing long-term maintenance.

For Pioneer Construction, the use of ThermoDeck represented a new system. Successful implementation required close coordination during installation, with teams aligning on sequencing and detailing to ensure consistent results across all buildings.

The outcome reflects that effort, a clean, efficient system that supports both performance and appearance.

On two of the buildings, horizontal ThermaClad panels were incorporated to introduce variation and create a more architectural expression. These elements help distinguish key areas of the campus while maintaining overall consistency.

Designing for brand and experience

While manufacturing drove much of the project, customer experience played an equally important role.

The expansion includes a fixed-base operator facility, restaurant and engineering office space, creating an environment where clients can engage directly with the brand. These spaces are designed to reflect the craftsmanship and history of WACO Aircraft while supporting modern expectations.

Two of the hangars feature “vintage look” façades, reinforcing the company’s identity and connecting the new construction to its heritage.

A graphic wall depicting engineering drawings is positioned along the customer approach, offering a visual connection to the design and precision behind each aircraft. This feature bridges the gap between production and experience, allowing visitors to see the process behind the product.

These elements demonstrate how the facility supports more than operations. It supports how the company presents itself to the world.

Built for what’s next

The completed expansion provides WACO Aircraft Corporation with a campus that supports production, assembly and customer engagement within a single, integrated environment.

The new facilities allow the company to accommodate increased demand, introduce new product lines and create a more engaging experience for clients. Each building contributes to a larger system designed for efficiency and growth.

Recognized through its successful execution and outcome, the project reflects what can be achieved when planning, coordination and adaptability remain aligned from start to finish.

For Pioneer Construction and Varco Pruden, the project demonstrates a practical approach to complex expansion, one that brings together multiple buildings, systems and goals into a single, cohesive solution.

The result is not just additional space. It is a campus designed to support how the business operates today while preparing for what comes next.