AALTO, the aerospace innovator behind the world’s most advanced high‑altitude, solar‑powered aircraft — the fixed‑wing High Altitude Platform Station (HAPS) Zephyr — turned to DomeShelter Australia for ground infrastructure capable of matching the ambition of its record‑breaking program.
The site chosen for the hangar was within a conservation area near Mt Kenya, where careful consideration of the environment shaped every decision, including SPS and AALTO’s decision to engage with DomeShelter Australia on the project.
Out of all the providers they considered, DomeShelter Australia was selected because of our in-house engineering and manufacturing capabilities, and ability to deliver a solution that balanced proven performance with minimal environmental impact and facilitate eventual site rehabilitation.
Credit: AALTO
The Challenge
The project carried a distinct set of pressures:
- Sensitive Location – Building within a conservation zone meant the structure had to be designed for minimal disturbance. Footings and flooring needed to be relocatable, ensuring the land could be restored if the hangar was ever removed.
- Asset Protection – Zephyr required a fully enclosed, weather‑tight hangar capable of withstanding the East African climate — marked by seasonal heavy rains, strong winds, and intense UV exposure while providing smooth access for deployment, maintenance and storage.
- Rapid Deployment – AALTO’s program milestones meant SPS worked to tight deadlines. The shelter had to be manufactured in Australia, shipped to Nairobi, and installed by onsite teams.
- Visual Integration – The conservancy requested that the hangar blend into the landscape. Standard white fabric was replaced with green to soften the structure’s visual impact.
- Remote Location – The project had to be transported to and assembled in a remote conservation area near Mt Kenya, requiring robust export logistics and a solution engineered for straightforward installation far from major infrastructure hubs.
SPS and AALTO turned to DomeShelter Australia because they needed a solution that could deliver on all fronts — engineered strength, fast delivery, and environmental consideration.
The DomeShelter™ Solution
DomeShelter Australia designed and delivered a fully engineered 32m × 24.4m Truss DomeShelter™ Structure, container-mounted for stability and agility. 
Dimensions & Design
- Width: 32m | Length: 24.4m | Total Height: 7.6m
- Mounting: Single-stacked ISO containers positioned externally
Integrated Features
- Endwalls & Doors: Full framed endwall with 30m-wide sliding door system (4m high), plus personal access door.
- Weather Management: Integrated guttering with downpipes for rainwater control.
- Installation: Step-by-step instructions, with all components pre-engineered and securely packed for export.
Structure & Materials
- Framework: High-tensile Australian steel truss hoops, hot-dip galvanised for corrosion resistance.
- Fabric: Armourtex® 400FR tear-stop fabric — fire-retardant, UV-resistant, tensioned with stainless-steel ratchets.
- Environmental Fit: Custom green tarp selected to visually integrate with the conservancy.
Credit: AALTO
Ongoing Modifications
Since the initial delivery, DomeShelter Australia has continued to work alongside SPS and AALTO as their program evolves. The hangar is now being modified to meet new demands, including a 12‑metre extension at the rear and a shift from single‑stack to double‑stack container mounting. These changes illustrate how the structure can be re‑engineered in step with the project’s growth, ensuring the shelter keeps pace with AALTO’s expanding operational requirements.
Outcomes
Minimal Site Impact
Container mounting, relocatable pad footings and portable flooring allowed the hangar to be installed and removed without permanent damage to the conservation site. This approach also ensured the land could be rehabilitated quickly and fully once the structure was no longer required.
Reliable Asset Protection
The Zephyr HAPS is now housed in a secure, fully engineered DomeShelter™ Hangar that shields it from rain, wind, and UV exposure while allowing for smooth access, maintenance and deployment.
Agility and Adaptability
The project also demonstrated the agility of DomeShelter™ Solutions. From rapid initial deployment to the subsequent redesign now underway, the hangar has proven capable of evolving with AALTO’s program needs. This responsiveness underscores our ability to deliver infrastructure that grows and shifts in step with our clients projects.
Record-Breaking Flight Deployment
AALTO’s record-breaking 64-day flight in 2024 was supported by this DomeShelter™ Hangar, which provided the secure environment and operational reliability required for such a milestone. The project played a direct role in enabling the success of the flight by ensuring the aircraft was protected and ready for deployment.
Fast Delivery and Deployment
DomeShelter Australia’s established global sales team and trusted logistics network, which has delivered more than 100 projects to 25 African nations, ensured the structure was manufactured in Australia, shipped in secure stillages, and delivered to Nairobi on schedule.
Environmental Synergy
The custom green Armourtex® 400FR cover ensured the DomeShelter™ Hangar blended almost seamlessly into its natural surroundings, meeting conservancy requirements while maintaining aerospace-grade reliability.
This project represents how fit-for-purpose infrastructure can accommodate stringent aerospace requirements while respecting the surrounding environment.
With this project, DomeShelter Australia once again proved its ability to deliver engineered solutions that balance operational reliability with site-specific sensitivity—whether in Africa’s remote conservancies or industrial hubs worldwide.
Contact our global sales team today to discuss how a DomeShelter™ Solution can be engineered for your site, sector, and standards.
Credit AALTO
