A Look Ahead: PEMB and Aerospace Manufacturing
How Modular Pre-Engineered Metal Buildings Will Transform Aerospace Manufacturing Facilities by 2030
1. Demand for aerospace manufacturing facilities is growing rapidly.
According to the 2025 Forecast from Aerospace Manufacturing and Design, several indicators point to a sustained period of growth in the aerospace field:
- Commercial airline traffic is expected to exceed 10 billion passengers worldwide (up 6 percent over 2024).
- Global revenue for the airline industry is expected to reach $1 trillion for the first time.
- The Global commercial fleet is expected to grow by 3 percent annually over the long term.
Meanwhile, the global space economy reached a milestone $613 billion in 2024, growing at 7.8 percent year-over-year.
Leading the way in that field are companies such as Elon Musk’s SpaceX (Space Exploration Technologies Corp.), which grew by 63 percent in 2024, posting revenue of $14.2 billion.
As people worldwide rely more and more on air travel—and the frontiers of space become more and more accessible—aerospace construction will continue to increase.
2. Modular PEMBs are ideal for accommodating growing aerospace demands.
The modular designs of today’s PEMBs offer several advantages for aerospace manufacturers:
- PEMBs can be erected quickly in response to changing market demands.
- Modular designs allow for flexibility in expanding or reconfiguring buildings as needs shift (for example, changing from aircraft to satellite production).
3. Modern PEMBs can meet the rigorous standards of aerospace construction.
The Benefit of Wide, Open Spaces
Clear span construction has always been one of the most appealing and distinctive features of PEMBs. The unobstructed interior space afforded by clear span design makes PEMBs an especially good fit for industries that work with large objects—such as aerospace.
Meanwhile, recent advances have drastically increased the scale of clear spans available for PEMBs:
- Modern frames employ steel alloys with superior strength-to-weight ratios.
- Tapered columns and rafters can minimize steel usage while preserving the necessary strength.
- Computer-aided design enables builders to compute load requirements with greater precision.
As a result, today’s clear spans can achieve widths of 300 feet or more. This is crucial for an industry that builds large commercial airliners, rockets, and satellites.
How Today’s PEMBs Handle Crane Loads
Moving and fitting the components of large objects such as commercial airliners requires the use of specialized cranes. These huge pieces of equipment impose extraordinary loads on the buildings that house them. The structures must be able to bear the weight of the cranes themselves, along with whatever components they carry. They must also handle the force of vertical and horizontal movements as the cranes do their work.
Modern PEMBs meet this challenge through a variety of means:
- Cranes are often mounted on tracks or runways that connect to the building’s main beams, distributing the load.
- Cranes can also be mounted on freestanding structures that bear the entire load independently.
- Foundations are engineered with the anticipated loads in mind. They can be strengthened to accommodate the presence of cranes and other heavy equipment.
Aerospace construction is one of the most technically demanding fields in the world. It requires a strictly controlled environment and the ability to meet exacting standards of precision, safety, and cleanliness.
Here are just some of the requirements for a viable aerospace facility:
- Cleanliness. Some aerospace construction activities require an immaculate environment to prevent contamination, especially from unwanted particulates. The ISO 5 cleanroom standard limits the number of particles per cubic meter allowed. PEMBs can meet this requirement by controlling air flow and using high-efficiency air filters.
- Controlled Climate. Some processes require strict limits on temperature and humidity. Modern PEMBs meet these requirements by using state-of-the-art HVAC systems along with effective insulation and vapor retarders.
- Safety. Beyond the OSHA safety standards that apply to any industrial entity, aerospace facilities must meet the extremely exacting requirements of the Federal Aviation Administration (FAA). Millions of people rely on the safety of the aircraft these facilities produce. Consequently, aerospace is one of the most highly regulated industries in the world. PEMB builders must coordinate with the FAA regarding construction requirements for aerospace-related projects.
Toward 2030: What to Watch For
The growing aerospace market will require several features in the buildings of the future, including:
Sustainability.
PEMB integrates well with solar and other sustainable energy sources. With the use of high-efficiency insulation and reflective coatings, PEMBs can provide the best of sustainable technology.
Shorter lead times.
PEMBs can now be designed with tech infrastructure pre-wired, simplifying their outfitting for aerospace use.
Smart building capabilities.
When manufacturers need to respond quickly to market shifts, PEMBs offer the ideal option. Their fast construction times and adaptability are a perfect fit for this dynamic industry.
Cost predictability.
Since PEMBs are designed and fabricated in a controlled factory setting, their major costs can be known beforehand.
Lifecycle value.
Durable materials and efficient design features (e.g., incorporating fewer joints and minimal roofing seams) reduce the longe-term maintenance needs of PEMBs.
Future-Ready Buildings
Designed for today, engineered for what’s next.
The Fleming team has completed more than 100 aviation industry and aerospace projects for clients ranging from the National Guard and the US Air Force, to a host of confidential, high-visibility aerospace clients. As PEMB specialists, the professionals at Fleming are focused on long-range aerospace trends — building spaces that support R&D, assembly, and logistics under one roof. Backed by a nationwide subcontractor network and rapidly deployable teams, Fleming brings the scale, expertise, and resources to deliver aerospace and aviation projects of any size to successful completion.
