AIRCRAFT RE-DELIVERY CENTRE IN KAUNAS

MAAS Aviation, a company with more than 30 years of experience in aircraft painting and exterior coatings has recently expanded its business in Lithuania, at Kaunas Airport territory. The purpose-built paint shop designed by TEC Industry pushed Kaunas towards the status of world-class MRO center.

The two-year long cooperation of MAAS Aviation, TEC Industry and TEC Consulting, SE Lithuanian Airports and other participants of this project is crowned with the most modern MAAS Aviation paint shop at Kaunas Airport. The MAAS Aviation facility project was prepared by TEC Industry. The technical supervision of the construction works of the facility was performed by the TEC Consulting team. A very modern object was built in eight months. The facility can accommodate up to two A321-sized aircrafts at the same time and is the first such paint shop in Lithuania. It became the eleventh company paint shop in the world.

Project presented challenges

This exceptional project at Kaunas Airport raised multiple challenges for its designers: the largest of them became the 41 m span. In this respect this industrial building is truly exceptional in Lithuania. “We searched for the most appropriate solution for such lengthy trusses in several computer-aided design and modeling programs. Finally we modeled structures that would be both economical and load-bearing according to the specified requirements”, – Mantas Biknius, TEC Group Sales Manager, recalls the search for the most acceptable option. Best-in-class paint shop has been completed, and the strength of the structures was also checked by winter, abundant with heavy wet snow this year.
Another challenge for the designers was the huge gates of the paint shop. The entrance for the planes to get in is the same 41 m spacing. The special frame formed from metal constructions must have to withstand not only the truss, but also the 41 m wide gate. “This construction has been implemented. The gate consists of three parts, the side parts rise in half, and the central one rises to the top so that the tail – the highest part of the plane – can enter unhindered” – M.Biknius comments on the interesting design process.

Activities demanding to lighting

An advanced technical solution for the gate was needed not only because of its size, but also because of the A+ energy class requirements under the current legislation for the new buildings. After considerable work with suppliers, the specialists of the TEC Group have found acceptable structural solutions for the gates of the unit. Paint shop gates are textile-made: they are of synthetic material with a layer of insulation. Thanks to non-standard solutions, it was possible to maintain the appropriate thermal resistance and the facility met the A+ energy efficiency class, despite the large surface area of ​​the gate. “There were also some challenges regarding the methodology for testing space of this size with a gate of this size and making sure that it complies with the A+ class. We have successfully passed the tests with blowers,” says the Sales Manager of the TEC Group.
The LED lights used in the building also increase its sustainability by reducing energy consumption. It is known that lighting is very important in the painting process, so the workshop is equipped with powerful lighting. On the surface of aircraft painting (about 20 meters from the ground) the necessary amount of lighting and sufficient color recovery had to be ensured. Standard LED lights did not fit here. In order to avoid glare, which was one of the most important requirements for the lighting system, dispersion panels emitting a uniform light flux were chosen instead of direct-spot light.

Technology ensures sustainability

The MAAS Aviation building, designed to achieve the highest quality standards in the sector, has not only specific lighting, but also sewage, ventilation, air supply and fire protection systems. All of them work together to ensure smooth operation and controlled environmental impact.
The paint shop controls the microclimate to minimize the risk of defects when painting aircraft. “A heating system controlled by gas burners ensures comfort not only in the common office premises, but also in the paint shop itself. Technologically, this is very important, because during painting, the exact humidity and temperature must be maintained, – notes M. Biknius, – Also, during the removal of old paint, a comfortable air flow must be ensured for people working on the aircraft. Deliberate air circulation allows the aircraft to dry faster between painting operations.” The supply of sufficient air flow is provided from above. The aim was to keep the air flow as laminar as possible not to create any eddies or drafts and to allow the paint to lie evenly on the surfaces.
A special system in the facility ensures air recirculation, which also increases the energy efficiency of the building. The paint shop is equipped with air intake filters at the bottom, front and sides of the aircraft parking lot. These filters collect paint splashes and clean the air. The recirculated air saves heat, and only the excess air, which has already been used several times, is released into the atmosphere. With the help of both recirculation and filters, it is cleaned of volatile organic compounds (VOCs) and thus ensures the sustainability of the building and its work without odor and pollutant emissions. The modern air purification system has been installed in cooperation with a company from England specializing in this field of activity.

Attractive to customers

Experts in aircraft painting and exterior coatings have opened a new paint shop at Kaunas Airport next to FL Technics maintenance and repair facilities. Basic maintenance and painting services available at the same airport are a cost-effective way for airlines to make the most efficient use of aircraft ground time.