When airplane maintenance leader AAR Corp was looking to build two maintenance hangars that would provide space for the largest commercial and military cargo planes, they chose Chicago Rockford International Airport in Rockford, IL, because its one of the countrys most densely populated areas of experienced aerospace personnel.

The Greater Rockford Airport Authority selected Rubb Building Systems from a number of options to design, manufacture and construct their new 200,000-sq. ft. maintenance and repair facility.  Airport structures in the area have traditionally been limited to design-build steel buildings or pre-engineered steel buildings. The Rockford Airport management team looked to Rubb Building Systems for the creation of two new structures that would dramatically change the landscape of the airport.

The 1,100 tons of columns, beams and all the peripheral steel is hot dip galvanized.  Working closely with fabricator Garbe Iron Works, the $40 million project is comprised of two, 10-story tall side-by-side identical hangars.  However, this project did not come without its challenges, specifically creating a structure that is able to support the large clear span needed to house a jumbo jet. In this case, the facility is comprised of two mega hangers that have interior dimensions of 300.7 feet by 300.7 feet each. The height of the hangers exceeds 100 feet, and the side walls reach heights of just under 40 feet. The dynamic arch structure has as its core a skeleton comprised of hot dipped galvanized steel, clad with 51-mm thick Thermohall insulated fabric.

The compressed turnaround times for the project sometimes only a few days and the windy days the erector had to endure trying to install the steel and the fabric covering also presented challenges.  However, all parties for this project worked together to meet the deadline.  The galvanizer, who has to wait until the last part of the project to complete the hot dip galvanizing, was able to meet the tight schedule requirements.

With the majority of airport maintenance facilities being relegated to a traditional building design, Rubb offered the Rockford Airport something unique.  Structures supplied by Rubb offer design flexibility and adaptation coupled with a cost effective means of long term corrosion protection.  The buildings integrate ventilation windows and conventional doors while providing massive clear spans with no center columns.  The translucent roofing is continuous, preventing water and air infiltration with no connection joints.  The hot dipped galvanized steel truss structure provides longevity, cost effectiveness and superior corrosion protection.  Additionally the hot dipped galvanized coating provides a consistent zinc finish on both interior and exterior steel surfaces creating the Rubb difference...rugged and reliable.  The hot dipped galvanizing will provide maintenance free corrosion protection for many decades in this suburban environment.

The Rockford International Airport is located just outside of Chicago, Illinois.  This area provides a home to a significant hub of the aviation manufacturing community.  Each of the Rubb structures is fitted with a five-panel mega-door with pivoting mullions that allow for access of up to an Airbus A380 jet. All steel components are hot dip galvanized to ensure consistent operation.

The Rockford project represents the largest structural project in Rubb USA's history.  This is extremely significant because Rubb is revered as setting itself apart from other manufacturers of fabric-coated structures with its commitment to being the premier provider.  The company aims to supply high-quality designs utilizing structures and materials that stringently meet and exceed local engineering and building codes.  Their steel structures are more durable than aluminum. Paired with a hot dipped galvanized coating, Rubb is able to offer longevity and superior corrosion protection. This speaks to the importance of hot dip galvanizing and places it in an important class all by itself.

The new facility was placed into operation in December of 2016.  Today, the Rockford Airport maintenance facility presents a unique appearance from the ground, as well as from the air.