Hawaiian Airlines

Honolulu International Airport (HNL), Hawaii

Rubb USA has constructed another signature aircraft hangar project at Honolulu International Airport (HNL).


Hawaiian Airlines, the State of Hawaii and HNL needed to expand their hangar and air cargo capacity and selected Rubb’s aviation buildings as the ideal solution. Because of space and growth constraints the project required a unique design. Hawaiian Air visited Rubb USA’s air cargo facility, which was built for United Airlines at HNL in 1997, to get an understanding of Rubb’s capabilities.


MCA Architects in Portland, Oregon, was brought on board to design the new MRO hangar and air cargo warehouse. The project required a diverse use of spaces including cargo, parts warehousing, aircraft maintenance, ground equipment maintenance, offices, training classrooms, and various other facilities.


Frank Rudloff, partner at MCA Architects, noted: “They wanted to redevelop their home base at HNL and wanted to take a look at Rubb’s technology.”


Rubb then designed, manufactured and constructed a maintenance hangar with a length of 105.7m (347ft) and an air cargo facility at a length of 57.9m (190ft). Each aviation building features a clear span width of 83.8m (275ft).


Rubb’s technology provides long term benefits superior to traditional construction. Considering Hawaii’s challenging natural environment, a corrosive marine environment with high winds and rain, not to mention high UV exposure, Rubb provided a solid solution: a corrosion resistant structural framework with a high quality translucent PVC cladding, which allows natural light to enter while reflecting the solar load.


Also, due to the shallow volcanic and coral base at the site, the foundation requirements for the building had to be flexible, another positive feature of Rubb buildings. The true milestone of this project was Rubb’s ability to successfully synergize with HNL, State of Hawaii, Hawaiian Air, and MCA Architects along with a local construction contractor to see this project through.


“It’s always a challenge to do major improvements to an active airport. The program was designed in a sequence so that certain projects would be completed to allow for other projects to begin and at the same time keep operations running 24/7,” said Carolyn Sluyter, Public Information Officer, State of Hawaii.


The new facility consolidates Hawaiian Airline’s existing cargo operations, aircraft maintenance, loading docks and customer service operations into an integrated facility. As HNL continues to grow, the Rubb hangar may be expanded by adding trusses and extending the fabric roof.

Building Specifications



Storage / MRO






275 ft



347 ft



Assa Abloy




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