Trial complete: RPAS hangar ready for deployment

Last year, Rubb UK secured an order from NATO and the RAF for two 30m x 21m EFASS hangars to support the very first global deployments of the RAF’s Protector RG1.

Ahead of their deployment, the Rubb team setup an on-site trial in our Gateshead facility to prototype the new model. Two mammoth 30m-span modules and a fully-functioning Heli-Door were installed in our yard as we began the lengthy process of prototyping the next generation of unmanned aircraft hangars.

With the trial complete, the Rubb team sat down to discuss lessons learned.

A new approach

“We wanted to capture everything that we’ve developed and learned with all of the other hangars, and put it into one more up-to-date package that would be useful across the board,” says Andrew Knox, Sales Director. The 30m EFASS was designed specifically for unmanned aircraft, with a wide span and low profile to accommodate larger wingspans.

Ian Hindmoor, Managing Director, adds, “Our existing products worked well for fixed-wing and rotary aircraft, but this is tailored for RPAS. Larger wingspans, low profile. Exactly what the 30m provides.”

Worldwide deployment

Bryan Davis, Military Project Lead, points out the technical challenges: “The size of the door and the wind loads it has to withstand make this hangar much more complex than previous models.” The structure is built to handle wind speeds of 41.6m/s and snow loads of 100kg/m², meeting Eurocode standards.

The Heli-Door, with a clear opening of 30m by 6.8m, opens in two minutes, allowing quick turnaround for RPAS missions. All of this can be supported by an integrated backup generator. “This ensures the RPAS can stay in operation no matter what,” Bryan adds.

Thermal efficiency is achieved through Rubb’s Thermohall® PVC system, and the hangar is designed for easy shipping in 20ft ISO containers. “The packing arrangement was developed with the UK military, so it can be shipped by air, land, or sea,” says Andrew.

“It’s still very much a containerised, deployable hangar, but it’s got more capabilities to go worldwide,” Ian explains. “What we have now is the biggest deployable structure that this company has ever developed.”

Collaborating for success

The 30m EFASS was shaped by feedback from RAF 5001 and 31 Squadrons. Andrew notes, “Input from the squadrons on electrical supplies, installation methods, and operational requirements was invaluable. It helped us address real-world challenges and refine the design.” Ian adds, “Based on our lessons-learnt scheme with 5001 Squadron, we looked at components that needed regular maintenance and designed those out for easier access and reliability.”

Prototyping and the on-site trial allowed the team to make rapid adjustments. “You can take drawings and ideas back to the engineers and get them implemented the same day,” says Bryan. “Lots of things can be determined on a drawing board and visualised, but the most effective way of prototyping and research and development is to actually build a prototype,” adds Ian.

The collaborative process involved the installation, design, and production teams working closely across the entire trial period. “I’m very proud of how the team came together to create the product we have today,” says Ian. “We developed not only the product itself but also the methodology for building it.”

Built for the future

With our yard now cleared and the first 30m EFASS hangar ready for operational deployment this year, the whole process has been invaluable for Rubb.

“Overall, I think the experience will help us in future projects, from what we’ve learned from the contractual side with NATO to having the confidence and experience in the R&D work we’ve done,” Andrew begins. “The way everybody pulled together on this project as a company has shown that we can take on anything.”

The project brought together expertise from across Rubb, our partners, and RAF 5001 and 31 Squadrons, resulting in a deployable hangar that meets the needs of today’s unmanned aircraft operations. The contract continues Rubb’s relationship with the UK Ministry of Defence and highlights its commitment to British manufacturing.

“This is a huge step forward for Rubb, bringing together years of experience and feedback from end users. Securing this order for NATO and the RAF is a significant milestone. We’re proud to support the deployment of the Protector RG1 with a hangar system built for the future,” Ian concludes.

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