Projects

51′ Monopole Extension & PoleMax Reinforcement  |  Elkin, North Carolina

Project Description:

This monopole is located in Surry County, North Carolina and provides cell coverage for the Surry area. This project focused on providing a turn-key solution for the structural modification and placement of new antennas on an extension and equipment to support the cell carrier’s effort to provide improved cell coverage to the Surry area.

Aero Solutions Role:

Aero Solutions provided a turn-key solution to bring the tower into compliance with the new antenna loading using non-welded reinforcing elements. The existing monopole was extended by 51 feet to bring the total height to 195 feet. Twelve new panel antennas were installed onto the steel extension at a height of 195’ feet. Due to the new wind area of the antennas, the lower sections of the monopole also required structural reinforcement using the Pole Max® channels. Bolted channels were installed symmetrically around the pole from 13 – 48 feet, and again from 40 – 146 feet. The existing 5 foot shaft extension and flange at the top of the pole had to be removed. In addition to the new loading at 195’, the existing mount at 153’ had to be temporarily removed and reinstalled and the same elevation. All carriers remained in service during the modification upgrade and extension installation.

Technical Description:

Tower Type: Monopole
Height: 195 Feet

Aero TRS Leg Reinforcement 

Project Description:

The Aero TRS reinforcing system was developed specifically for increasing capacity of the lattice type legs of Pirod Towers. Aero’s proprietary TRS reinforcing system is installed between flange connections (20 foot typical) and consists of twin tubes installed and braced against the existing leg structure. All connections are bolted onto the flanges and tower structure, eliminating any requirements for welding on site. Aero has completed multiple TRS projects sites in the continental US and Puerto Rico. This reinforcing system is specifically used on self support structures.

Technical Description:

Tower Type: Self Support Tower
Height: Unrestricted

Lattice Tower Upgrades at Hoover Dam  |  Nevada-Arizona Border

Project Description:

This tower is located adjacent to Hoover Dam and provides cell coverage for this area. To improve cell coverage at this location, a cell carrier contacted SBA Communications with a request to collocate an additional 18 panel antennas on the structure at 212 feet and an additional 12 antennas at 245 feet. SBA Communications evaluated the structure with proposed loading and determined the tower was structurally insufficient for the new antennas. Given Hoover Dam’s status as National Critical Infrastructure and increased security measures, a limited construction window was granted that required a solution providing expedient installation with minimal carrier disruption. This project focused on providing a turn-key solution for the modification and placement of new antennas and equipment to support the cell carrier’s effort to provide improved cell coverage in the area.

Aero Solutions Role:

Aero Solutions provided a turn-key solution using non-welded reinforcing elements to bring the tower into compliance with the new antenna loading. An engineered bolt-on solution was developed to reinforce the tower at elevations of 0-50 feet, 143 feet, 183 feet, 199 feet and 213 feet. Aero’s modification was completely non-welded, eliminating any risk of fire and increasing the safety at this sensitive site. Upon completion of the modification, the tower overstress ratios were lowered to below 100 percent.

Technical Description:

Tower Type: Four-sided self support
Height: 265 feet
Modification Date: 2006
Client: AAT Communications  [ Tower now owned by SBA Communications ]

Carbon Fiber Reinforcement Technology  |  Lexington Park, Maryland

Project Description:

The 320 foot tall guyed tower required leg strengthening to resist buckling from its base to 260 feet in height and rotation of the tower by 60 degrees. The existing coax cable supported from the legs was a serious fire hazard if the proposed welded steel half pipe originally designed was installed. Aero value engineered the existing design to a reinforcing system using carbon fiber shells bonded to the tower legs. Each leg was strengthened using two 150 degree half shells structurally adhered to a roughened galvanized surface. The shells were manufactured by Aero affiliate Comptek Structural Composites, Inc. using vacuum molding. Each shell was 18’-6” in length with a wall thickness of .125 inches. The structural adhesives were placed onto the shells on the ground prior to raising an placement.  Following the installation of all carbon shells, a polyurethane wrap was helical wrapped around the reinforced leg members as added protection. To facilitate the sites available land space with the installation of new guy cables, the entire tower was rotated 60 degrees around its axis. 

Aero Solutions Role:

Aero was the Design/Builder responsible for developing the engineered solution, material fabrication/manufacturing and installation.

Technical Description:

Tower Type: Three leg guyed tower
Height: 320 feet
Client: Crown Castle International

Skyscraper Broadcast Monopole Restoration  |  Honolulu, Hawaii

Project Description:

In the summer of 2010, Aero Solutions installed carbon fiber wrap and 145’ of grout reinforcement to this monopole in Honolulu, HI, located on top of an office and residential building in downtown Honolulu. Aero not only reinforced the existing monopole but provided technical and engineering support. We installed all the transmitting equipment and new antennas for this local television station. This project logistically had a large amount of moving parts and different factors to consider throughout. Most notable were the 26 helicopter lifts consisting of 800 lbs of grout for each lift, to the roof of the building, all being completed within 48 minutes. While respecting the environment, the surrounding city and adhering by the highest safety standards, Aero successfully reinforced and installed all new antennas and transmitting equipment.

Aero Solutions Role:

Aero was responsible for overseeing material fabrication, shipping and installation.

Technical Description:

Tower Type: Monopole
Tower Height: 190 feet
Total Height: 501 feet
Client: New Vision Television, KHON-TV

International: Bermuda 275’ New Build Tower  |  Bermuda

Project Description:

In 2007, Aero Solutions was awarded the turn-key construction of 275 ft, six-carrier self-support tower. This included site civil works, foundation installation, tower erection, and lines and antenna work. Aero also developed tower design specifications, managed client’s tower fabrication and challenging installation conditions in the field.

Aero Solutions Role:

Initial project estimating and program coordination with the customer, management of tower fabrication and QA/QC process, managing project schedule, vendor compliance, client interaction and reports, on-site project manager directly overseeing all subcontractor labor.

Technical Description:

Tower Type: Self Support
Tower Height: 275 feet
Client: Digicel

International: United Nations Infrasound Projects  |  Bermuda

Project Description: 

The signing of the Comprehensive Nuclear-Test-Ban Treaty in September 1996 and the establishment of the International Monitoring System (IMS) has led to a rapid development in the use of infrasound monitoring technology for the detection of nuclear explosions. The IMS includes 60 stations equipped with high-sensitivity equipment, located around the globe, designed to detect infrasonic signals from nuclear explosions. This project focused on providing a total turn-key solution to support station installation, including material procurement, site construction and installation of the equipment in Bermuda.

Aero Solutions Role:

Aero Solutions provided a turn-key solution for the installation of four monitoring sites and a fifth central recording facility located in Bermuda. Two 30 feet self-support towers and two environmentally friendly wood poles were used to support the communication systems antennas and solar panels for the site power. Aero managed the zoning, site design, planning, material fabrication, logistics and installation of all five sites.

Aero has also recently been awarded a new contract with the CTBTO to build an infrasound station in the Azores, Portugal.

Technical Description:

Tower Types: Self-support towers and wooden poles
Client: United Nations, Comprehensive Test Ban Treaty Organization (CTBTO)