The aeroplane is the safest mode of transport? True. And to keep it that way, constant maintenance is necessary. But: how do you transport the approximately 275 tonnes of empty weight of an Airbus A380 for regular check-ups? Where do you store its 73-metre length? And what if the aeroplane is out of action? The Elbe Flugzeugwerke Dresden recently provided the solution: a mobile hangar. What does this have to do with hairline cracks and galvanising? More on that later.

Initially, Elbe Flugzeugwerke Dresden, a subsidiary of the European aerospace and defence group EADS, decided to expand its spatial capacities for the maintenance of the Airbus A380. However, difficult space constraints made a simple hall expansion impossible. Any extension would encroach on the adjacent airfield. The solution: a mobile hangar, flexible like a large sliding door. A unique idea – with a unique challenge.

Stahlbau Brehna GmbH took on the contract – with the help of Voigt & Schweitzer in Landsberg. This was because 240 tonnes of steel had to be hot-dip galvanised for the project. A challenge.

„Especially with structures of this size, it is particularly important that the components are optimally protected against corrosion for their entire lifespan. The constant shifting of the hangar can damage the steel struts and create surfaces for rust to attack. High-quality galvanising is therefore essential,“ explains Sven Biebler, Managing Director at Voigt & Schweitzer.

„For our ZINQ experts, this is naturally no problem: demanding tasks in structural steel construction and projects with large tonnages, as well as corresponding project durations, are our speciality.“

Because for the most demanding requirements too, there is a solution – in this case, it lay in logistics. A masterpiece, as the large components had to reach the customer particularly quickly and safely, and above all, without unnecessary transport routes.

No sooner said than done: Under the project name „Mobile Hangar 285“, the approximately 240-tonne steel beams reached the galvanising works in Landsberg to take a dip in liquid zinc. More precisely: in duroZINQ®. Characterised by high product quality in terms of appearance and function, as well as exceptional longevity, duroZINQ® surfaces on steel last a lifetime and reliably and permanently protect steel from corrosion. Perfect for a sophisticated construction like the mobile hangar. This is mainly due to the elimination of maintenance measures during the use of the hot-dip galvanised steel. In this way, duroZINQ® becomes the most ecologically and economically favourable process in surface technology.

For the smooth running of the entire order, delivery and collection are naturally also of great importance:

„Flexible processing in the shortest possible time and the highest quality are a must for our requirements, especially for large-scale projects such as the hangar for Elbe Flugzeugwerke,“ points out Matthias Gabler, Managing Director of Stahlbau Brehna. „This is not a contradiction for Voigt & Schweitzer, and so we have trusted in our joint co-operation since 2001.“

The galvanizer and the customer must work hand in hand, from consultation and planning right through to the implementation of the complete system. Because only then can the customer be sure that their orders will be fulfilled to the highest standards. And only with expertise and competence can optimal protection be guaranteed while maintaining the highest quality.

No problem, Voigt & Schweitzer guarantees a constant and reproducible quality, executed in specialised works, including according to ISO 1461. This must be convincing:

„The biggest component in galvanising is the quality of the finished surface. The galvanised item, the colour – that's what the customer sees first and by which they judge the quality. And that, along with the visual and technical functionality of the zinc surface, is heavily dependent on the company carrying out the work,“ explains Matthias Gabler. „There's no doubt that Voigt & Schweitzer and duroZINQ® are the right partners for us.“

Now, on to hairline cracks. After nine A380 aircraft had to be recalled and inspected due to very fine cracks in their wings, there was a loud demand for a quick, simple, and, above all, effective repair solution. The mobile hangar therefore came just in time. Freshly galvanised, it was the only one of its kind in Europe and could be erected and put into „operation“ at Elbe Flugzeugwerke Dresden. The first Airbus flew in directly and was repaired under the protection of the steel refined with duroZINQ®, with eight more to follow shortly. Thus, Voigt & Schweitzer will not only protect steel from corrosion in the future, but also wings from fatigue.