1. The Problem
Our defense customer needed a large repair shelter that could be easily relocated and deployed. This shelter had to be modular, low maintenance, adaptable to different climates, and provide sufficient space for their operations. Specific temperature requirements were also clearly specified: the shelter needed to maintain an internal temperature of 61°F in cold conditions (with external temperatures as low as -22°F) and 72°F in hot conditions (with external temperatures as high as +104°F). At that time, none of our products were large enough to meet the customer’s size requirements.
2. The Challenge
The challenge was to design and supply an inflatable hangar repair shelter that met the customer’s stringent requirements and technical specifications. The shelter had to consist of a pneumatic structure and a cover sheet, and it needed to be easy to assemble and disassemble by trained operators. Additionally, the shelter had to withstand harsh climatic conditions, be waterproof, and allow for easy replacement of components subject to wear or damage.
The shelter and its equipment had to be designed to endure a range of challenging conditions, including heavy rainfall of up to 4 in/ft², a snow load of 5 lbs/ft², wind gusts of up to 50 mph, and air temperatures ranging from -22°F to +104°F. These specifications ensured that the shelter remained intact and functional even in extreme weather conditions.
3. The Approach
The production, engineering, and purchasing departments worked together to analyze the customer’s requirements and identify the best approach. They chose AZM low-pressure inflatable shelters, which are known for their stability, generous internal volume, and ease of transport.
Inflatable shelters offer a reduced weight compared to metal frame structures of similar size and performance. This advantage makes them easier to transport and use. Additionally, inflatable shelters are low maintenance and require minimal upkeep over time. The ease of assembly and disassembly of the shelters contributes to their user-friendliness. They can be quickly erected and dismantled as required, enhancing their portability and allowing for easy movement both when packed and fully assembled.
Thanks to water-repellent materials and High-Frequency Welding (HFW) assembly technology, inflatable shelters are highly waterproof. Critical areas such as windows and doors have been specially designed to provide effective protection against water penetration.
Moreover, the inflatable shelter allows components to be quickly replaced in the event of wear or damage without the need for manufacturer intervention. This feature increases comfort and reduces downtime, ensuring that the shelter remains operational and effective in various conditions.
4. The Result
The supporting structure of the shelter is ingeniously designed using pneumatic elements, which are inflated through valves conveniently located near the base of the arches. The structure comprises pneumatic arches divided into five sectors, forming a sturdy gabled roof shape. These arches are interconnected by three tubular inflatable spacers along the roof ridge and above the gutter lines, ensuring stability and durability.
Each arch operates independently, which is a crucial safety feature. This means that, even if one arch fails, it does not compromise the integrity of the entire structure. Each arch, with a diameter of 24 inches, is constructed from seven tubular sections of polyester fabric. This fabric is coated on both sides with PVC and welded together, providing strength and resilience.
To enhance thermal insulation and comfort, the inflatable structure is equipped with an internal insulating liner. This liner is made from several sections of fire-retardant fabric that boasts excellent thermal insulation properties. Notably, the fabric does not absorb grease, oil, or other liquids, making it easy to clean and maintain. The thermal liner is essential for reducing energy consumption, as it helps maintain ideal temperatures inside the shelter regardless of the external climate.
The shelter’s inflating system includes three electric inflators and the necessary inflation hoses. Inflation and deflation are straightforward processes, facilitated by a simultaneous inflation kit. This kit connects to the inflators via simple pressure connections and consists of three polyurethane branches with an internal diameter of 0.80 inches. These branches are connected to a quick connector for easy insertion into the inflator vents.
The heating, ventilation, and air conditioning (HVAC) systems are fully equipped with all the necessary accessories for efficient operation. The HVAC kits include flexible tubing (hoses) to supply hot and cold air to the shelter. These hoses are insulated, and connectors are provided to ensure reliable connections between the HVAC equipment and the shelter openings. All HVAC equipment is designed for easy operation outside the shelter, ensuring a comfortable internal environment.
Conclusions
The hangar successfully met the customer’s requirements by offering key features such as the possibility of relocation, adaptability to different climatic conditions, low maintenance, and efficient use of space. The successful delivery and use of the inflatable hangar repair shelter have significantly strengthened our partnership with this customer. The versatility, cost-effectiveness, and mobility of inflatable hangars make them indispensable, particularly in military contexts where adaptability and mobility are critical factors.
This innovative solution not only meets the customer's immediate needs but also sets a new standard for portable, durable, and efficient repair shelters. The ability to quickly deploy and relocate these structures ensures that they can be used in various challenging environments, providing reliable shelter and operational space wherever needed. With the successful deployment of the hangar, we have decided to turn this product into a permanent product within our range.
You can learn more about our inflatable hangars by visiting our website.
