MRO and aviation professionals have been reaping the rewards of investing in Rubb aircraft and air cargo facilities. These fabric structures can be designed, manufactured and constructed to suit clients’ requirements, and have been the MRO and storage solution of choice for many high profile airlines, airports, operators and Maintenance, Repair and Overhaul companies around the world.
Hawaii maintenance and air cargo hangars support expanding operations
Rubb USA has created a maintenance hangar and an air cargo facility for expanding operations at Honolulu International Airport (HNL), Hawaii.
When Hawaiian Airlines, the State of Hawaii and HNL looked to vastly expand their hangar and air cargo capacity, they turned to Rubb for solutions. Because of space and growth constraints the project required a unique design. Hawaiian Air visited Rubb USA’s air cargo facility, which was built for United Airlines at HNL in 1997, to get an understanding of Rubb’s capabilities.
When the decision was made to move forward with the project, MCA Architects in Portland, Oregon, was brought on board to design it. The project required a diverse use of spaces including cargo, parts warehousing, aircraft maintenance, ground equipment maintenance, offices, training classrooms, and various other facilities.
Frank Rudloff, partner at MCA Architects, noted: “They wanted to redevelop their home base at HNL and wanted to take a look at Rubb’s technology.” The maintenance hangar features a length of 105.7m and the air cargo facility measures 57.9m long; each hangar provides a clear span width of 83.8m.
Rubb’s technology offers long term benefits superior to traditional construction. Considering Hawaii’s challenging natural environment, a corrosive marine environment with high winds and rain, not to mention high UV exposure, Rubb provided a solid solution: a corrosion resistant structural framework with a high quality, non-corrosive PVC cladding, which allows natural light to enter while reflecting solar load.
Also, due to a shallow coral base at the site, the foundation requirements for the building had to be flexible, another positive feature of Rubb buildings. However, the true milestone of this project was Rubb’s ability to successfully synergize with HNL, State of Hawaii, Hawaiian Air, and MCA Architects along with a local construction contractor to see this project through.
“It’s always a challenge to do major improvements to an active airport. The program was designed in a sequence so that certain projects would be completed to allow for other projects to begin and at the same time keep operations running 24/7,” said Carolyn Sluyter, Public Information Officer, State of Hawaii.
The new facility consolidates Hawaiian Airline’s existing cargo operations, aircraft maintenance, loading docks and customer service operations into an integrated facility. As HNL continues to grow, the Rubb hangar has the potential to be expanded by adding trusses and extending the structure.
Speed and flexibility of Rubb Buildings help Newquay Cornwall Airport respond quickly to MRO client’s requirements
A Rubb aviation MRO hangar has assumed a prominent position at Aerohub, a UK aerospace focused Enterprise Zone, based in Newquay, Cornwall. The fabric aviation building provides a large, bespoke space for Apple Aviation Group’s (AAG) increased Maintenance, Repair and Overhaul (MRO) operations.
Apple Aviation selected Aerohub at Newquay Cornwall Airport as the location for its aerospace maintenance facility headquarters.
The Rubb team constructed the main steel framework for the hangar and then fixed Thermohall insulated cladding to the structure to create its roof and walls. The hangar has the capacity to accommodate the storage, maintenance, repair and overhaul of large fixed wing aircraft such as a Boeing 757. A wide vertical lifting fabric door provides access to the hangar.
Managing Director of Rubb Buildings, Ian Hindmoor, said: “This is another flagship facility to utilize new Rubb technology such as the Thermohall insulated cladding. By working together with the contractors and clients, we have managed to achieve a topflight aircraft hangar we are all very happy with. The high specifications including the materials, engineering, door technology and internal services will ensure the MRO hangar will be used for many years to come.”
Al Titterington, Managing Director, Newquay Cornwall Airport, commented: “The speed and flexibility of the RUBB hangar construction has enabled the airport to develop new hangarage and respond quickly to a key customer's requirements. This has been critical in order for business to be undertaken in a competitive market place and puts NQY firmly on the MRO map with the capability to attract airlines to the facility.”
Rubb lands second Bristow order for fabric helicopter hangar
A respected helicopter operator company asked Rubb UK to design, manufacture and construct a helicopter hangar for operations at the Falkland Islands.
The Bristow Group needed a hangar to support oil and gas sector transport operations at Port Stanley Airport, Falkland Islands. The company has been successfully using a Rubb hangar at Norwich International Airport since 2010. Bristow bosses decided a similar fabric structure would be the best solution to house three Sikorsky S-92 helicopters at Port Stanley.
The new BVE helicopter hangar facility measures 39.5m span x 45m long x 6m to eaves. It features a 30m wide x 6m high manual sliding door. The hot dipped galvanized steel frame is clad with an inner PVC skin insulated with encapsulated rock wool designed to achieve thermal efficiency as specified in UK building regulations. The outer PVC membrane completes the structure.
Project Manager Andrew Maisalu said: “Rubb overcame various challenges to complete this project including extremely difficult weather conditions, remote site location and limited available access machinery to assist with the installation. However we were able to successfully complete the building, working closely with the local groundworks contractor.”
The hangar will be used to service, maintain and store the Bristow’s fleet of helicopters. It will also be used to support SAR operations and training exercises.