How is a Commercial Jetliner prepared for Long-Term Storage in the Desert?
Getting Ready for the Boneyard – 10 Steps
NOVEMBER 2024
Climate and Strategic Location
Goodyear Airport (GYR) on the outskirts of Phoenix, AZ, is a favorite choice for long-term commercial airliner storage. This is mostly due to its dry, arid desert climate and strategic location. The desert air significantly reduces the potential for component and system corrosion, which is a major concern for aircraft stored for extended stretches. Low humidity and virtually no rainfall in the region help to preserve an aircraft’s structural airframe, engines, and complex internal systems and workings, making it ideal for “stopping time,” as it were.
Retired Fleets
Goodyear’s proximity to key aviation hubs like Phoenix also provides logistical advantages for aircraft brokers, airlines, and aviation businesses that are determined to store or retire large aircraft. The airport is expansive in size and can easily handle large numbers of aircraft, making it the ideal site for both temporary- and longer-term storage needs.
Dismantling and Recycling
Additionally, airports like Goodyear deliver on the promise of a secure, well-maintained infrastructure with convenient access to specialized services, including aircraft repair and maintenance, dismantling services, and metal recycling. The airport has generous space available for parking multiple aircraft in a carefully organized grid system, maximizing the use of the available land while minimizing the risk of damage from other surrounding airplanes.
Favorable Weather
With its combination of unique desert weather, logistical accessibility, and vast specialized aviation services, Goodyear Airfield stands out as one of the true best options for storing and preserving commercial airliners in a secure and reliable way. Flying over the airport reveals the massive scope and nature of the operation.
Meticulous and Detailed Processing
Preparing a commercial narrowbody or widebody jetliner for an extended stay in an aircraft boneyard, also referred to as a storage “boneyard,” is a meticulous, complex, and detailed process. Aircraft parked for long periods must be painstakingly prepared to ensure that they remain in functional condition or at least prevent deterioration that would make them difficult or expensive to fly again. The storage process involves multiple steps, each intended to protect the airframe, engines, and various systems from the environmental impacts of corrosion, moisture, dirt, and dust.
1. The Final Flight
Before any aircraft is relocated to the boneyard, it must undergo a final flight or repositioning ferry flight to the actual storage location. This is important in helping to determine that the aircraft is indeed still in safe and flight-worthy condition. During this flight, any immediate concerns or issues are addressed as the aircraft is prepared for a transition to long-term dormant storage.
2. De-Identification and Legal Issues
One of the first things that must be done in the storage preparation process is to remove any identifiable markings, tail numbers, or paint. This typically includes removing airline liveries or logos, fuselage titles, and other branding marks to comply with legal or regulatory demands. The aircraft is also comprehensively documented, with records updated and revised to reflect its switch from operational airline service to desert storage.
3. Fuel Systems and Engine Shutdown
Next, fuel is drained from all main- and wing tanks to prevent it from degrading over time and eventually clogging the fuel system. This is particularly important since stale fuel tends to block lines and filters. The engines are also preserved during storage. In many cases, the engines are either completely removed from the airframe and stored separately, or they are entirely sealed and treated with special preservative oils and protective covers to prevent corrosion and damage from the elements.
4. Landing Gear Protection
The landing gear is one of the most vulnerable components of any aircraft when it is stored for a long period of time. To stop the formation of rust and prevent mechanical failure, the landing gear is deep cleaned, lubricated, and treated with protective coatings. The tires are also, in some instances, deflated or sprayed with certain chemicals to prevent the degradation of rubber over time. The aircraft is typically lifted on jacks or blocks to limit the weight on its tires, preventing potential flat spots and tire damage.
5. Battery and Electrical Systems
Batteries, including the aircraft’s main system battery, auxiliary power unit (APU) batteries, and other emergency batteries, are either fully removed or charged up and disconnected. Electrical systems are carefully checked, where critical components are sealed or treated with corrosion inhibitors. Any avionics bays or electronic systems that could be negatively impacted by moisture are either removed or protected with desiccants.
6. Airframe and Exterior Preservation Efforts
The aircraft’s fuselage, wings, and other structural and system components are deep-washed and fully inspected for any signs of damage, defects, or wear. Once cleaned, protective coatings are applied to all critical areas to resist corrosion. The aircraft is then covered with a protective plastic sheeting material, or, in effect, shrink-wrap, especially around the nose and cockpit, helping to keep moisture, dust, and insects out.
7. Final Interior Preservation
The interior of a stored aircraft, including passenger seats, cabin carpets, and avionics, is cleaned and treated. Upholstery is usually sprayed with mildew-preventing chemical solutions while any loose items are secured or removed. The cabin is frequently sealed using protective covers that are placed over windows, air vents, and other openings to keep away any dust or moisture. Climate control systems are, in many cases, deactivated or drained of fluids to prevent unwanted mold and corrosion.
8. Seals and Inspections
Throughout the entire aircraft, seals, such as those typically found around cabin doors, windows, and cargo hatches, are closely checked and replaced if necessary to ensure they maintain an airtight seal. All hydraulic, pneumatic, and air conditioning systems are completely drained of fluids and then sealed to stop any contamination or the buildup of rust.
9. Storage Location Preparation
Finally, the aircraft is repositioned to its chosen desert-storage parking spot in its new dry, arid, or low-humidity environment. Aircraft storage facilities such as the Pinal Airpark in Arizona and Goodyear are perfect locations due to the dry climate, which helps to preserve costly fleets of aircraft. Planes are parked in designated areas, often with multiple rows of aircraft parked tightly near to one another.
10. Ongoing Maintenance and Monitoring Programs
Once settled into desert storage, an aircraft will undergo periodic maintenance checks to ensure that no damage has occurred and that systems remain in an ongoing state of preservation. These checks usually include inspections every three- to six months to ensure that all protective coatings are still intact, while engines are monitored to confirm that no pests or moisture have infiltrated.
Extending The Life of The Aircraft
To wrap it up, preparing a commercial jetliner for long-term storage encompasses a detailed sequence of steps and processes targeting the preservation of the aircraft’s structural integrity and systems. It includes draining jet fuel, sealing critical components, applying corrosion inhibitors, and ensuring environmental system protection. This exhaustive process extends the life of the aircraft and its systems, whether for eventual reactivation or ultimately dismantling for parts or recycling.
Cost-Effective for Airlines
At the end of the day, buying a used airplane can be a more cost-effective option for airlines or charter operators wishing to expand their fleets. Used aircraft are considerably less costly than new models, offering big savings, especially for discount airlines with budget constraints. Additionally, today’s modern airframes are designed to last for several decades, where many used airplanes are still in excellent flying condition, having very low flight hours.
Reducing Operational Costs
The availability of aftermarket parts, established and detailed maintenance records, and the potential for upgrades can further reduce operational costs. For airline operators, purchasing a used commercial aircraft also provides much faster airplane delivery than waiting for new aircraft manufacturer builds, allowing for rapid fleet deployment.
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