Steel Workshop & Storage Unit design & build for Repaero, Manor Royal, Crawley, Sussex

Carnegie Steel Buildings successfully designed and delivered a bespoke commercial steel building extension for Repaero, the specialist aircraft component repair division of Allaero, based in Crawley, West Sussex.

Allaero is a leading supplier of business aircraft parts, supporting aircraft operators, maintenance organisations, and flight departments across the globe. In 2018, the company established Repaero as its dedicated in-house repair facility, providing specialist aircraft component maintenance, overhaul, and testing services. As demand for these services increased, Repaero quickly outgrew its existing workspace and required additional operational capacity.

Rather than investing in expensive commercial premises in one of the UK’s most sought-after aviation locations, Allaero partnered with Carnegie Steel Buildings to explore a more cost-effective and practical solution. Our experienced design team proposed a purpose-built steel building extension that would maximise the existing site while minimising disruption to daily operations.

Our in-house architects developed a two-storey steel frame extension that transformed part of the existing car park into a modern workshop and warehouse facility. The design was carefully planned to retain the majority of the site’s parking spaces while significantly increasing the available workspace and storage capacity.

The project included comprehensive site surveys, planning and Building Control submissions, and full compliance with current fire safety and construction regulations. The new extension was designed to complement the existing building, creating a seamless appearance while improving access and operational efficiency throughout the facility.

As a specialist steel building contractor, Carnegie Steel Buildings provided a complete turnkey solution, managing every stage of the project from initial consultation and architectural design through to steel frame construction, warehouse extension, and final handover. The extended steel structure created valuable workshop space alongside additional storage facilities to support growing inventory and improve logistics.

Throughout the build, our project management team maintained regular communication with Allaero, ensuring complete transparency on progress, timelines, and key milestones. The completed commercial steel building extension has provided Repaero with the additional capacity required to support future growth, streamline operations, and continue delivering industry-leading aircraft component repair services.

This project demonstrates how Carnegie Steel Buildings delivers high-quality commercial steel buildings and industrial building extensions that provide businesses with flexible, cost-effective solutions for expansion without the expense of relocating.