First £1.34m RAF & NATO order for new 30m RPAS hangar

08-04-2025

Gateshead-based Rubb Buildings Ltd has expanded its military hangar capabilities with the development of the new 30m Expeditionary Forces Aircraft Shelter System (EFASS), a deployable system designed specifically for Remotely Piloted Air Systems (RPAS).

This latest addition to the EFASS range enhances Rubb’s ability to support next-generation unmanned aircraft operations. Its low-profile structure and wide door system is engineered to meet the needs of the Protector RG1, the RAF’s next-generation unmanned aerial system.

Research & development

Extensive R&D began in 2023, with several concepts on the drawing board. The team settled on a WW2-inspired design, taking cues from the 1940s’ blister hangars. These were among the world’s first prefabricated, portable military aircraft hangars designed by British architect Graham Dawbarn.

The blister hangar’s arched span was reimagined with the EFASS’ faceted profile, allowing the system to share components with our 25m model. This bolsters manufacturing and stock efficiency, while aligning with RAF 5001 Squadron’s existing installation expertise.

Rubb’s in-house vertical-lifting Heli-Door system also received an upgrade. A new 30.85m-wide by 8.92m-high system with a clear opening width of 30.19m was developed to match the Protector RG1’s low profile and wide span.

In another first for the EFASS range, the 30m-span system utilises compact 3m modules to withstand enhanced wind and snow load standards. Additionally, a bespoke electric kit has been designed to support the Protector RG1’s specific operational requirements.

The first 30m EFASS prototype was trialled at Rubb’s Gateshead HQ in November 2024 and saw the successful erection of two spans and one 30.85m-wide Heli-Door, complete with PVC cladding.

First £1.34m order secured

Following the successful trial, NATO and the RAF have placed a £1,345,000 order for two 30m x 21m EFASS hangars, each featuring 100mm Thermohall® insulation and a 30.85m-wide Heli-Door to each gable allowing uninterrupted runway access. These hangars will support the very first global deployments of the RAF’s Protector RG1.

The contract includes on-site training at RAF Wittering for 5001 Squadron, who are responsible for the rapid construction of Temporary Working Environments (TWE). 5001 Squadron’s cooperation has been instrumental to the development of the EFASS range, providing invaluable ‘boots on the ground’ feedback for over twenty years.

The 30m EFASS has also been developed in close collaboration with 31 Squadron—the RAF Waddington-based unit responsible for operating the Protector RG1—to ensure the hangar system meets their exact requirements.

This contract is the latest milestone in Rubb’s long-standing relationship with the UK Armed Forces, going back to 1979 when the RAF tasked the company to supply military buildings for the world-famous Red Arrows. Today, Rubb holds a £9.7m single-source contract with the MoD, supplying industry leading, deployable aircraft hangars and through-life support.

Supporting British manufacturing

The development of the 30m EFASS has been made possible with the expertise of our British supply chain. Rubb’s commitment to UK manufacturing has never wavered since we were first founded in 1977.

Key suppliers include EDMO, Anixter Fasteners and local suppliers Airowsafe, Birtley Galvanizing, Rotational Engineering, SMW, JK Lifting, and Elite Powder Coatings.

We are incredibly proud to introduce the 30m EFASS, a hangar designed specifically to support the next generation of unmanned aircraft operations. This latest development is the result of close collaboration with the RAF, ensuring we continue to deliver innovative, high-quality solutions for the defence sector. Securing this first order for NATO and the RAF is a significant milestone, and we look forward to supporting the deployment of the Protector RG1 with a hangar system built for the future.

For more information on First £1.34m RAF & NATO order for new 30m RPAS hangar talk to Rubb Buildings Ltd