What happens when aircraft are retired from service? The answer lies in aircraft boneyards, vast stretches of land where planes are stored, dismantled, or recycled. These sites, strategically located in dry climates, have become essential to the aviation industry, providing a final resting place for aircraft that no longer soar through the skies.
Aircraft boneyards are facilities dedicated to storing out-of-service planes. They play a significant role in an industry with constant renewal cycles, allowing valuable components to be reused while avoiding the accumulation of obsolete aircraft. These sites house not only planes that have reached the end of their operational life but also those awaiting reactivation or serving as parts sources for active aircraft.
The world’s largest aircraft boneyard is located in Tucson, Arizona, at Davis-Monthan Air Force Base, where the 309th Aerospace Maintenance and Regeneration Group (AMARG) operates. Known as “The Boneyard”, it spans over 1,000 hectares and houses more than 5,000 aircraft, mostly military. Arizona’s arid climate is ideal for preserving these planes, as it minimises corrosion and helps maintain parts in good condition for long-term storage or reuse.
Teruel Airport in the province of Teruel, Spain, is Europe’s largest aircraft boneyard, surpassing other storage and dismantling facilities across the continent. Teruel occupies the former Caudé Air Base, which served as a military base during the Spanish Civil War. Reconfigured five years ago as a long-term aircraft storage and recycling platform, Teruel Airport has seen investments of around €50 million and now spans 340 hectares, accommodating up to 400 aircraft.
The choice of Teruel as a boneyard location was driven by several factors. Teruel’s dry and mild climate is optimal for storing aircraft over extended periods, as it minimises corrosion. Additionally, its strategic location allows the airport to receive planes from both Europe and Asia, making it a vital centre for the aviation industry.
1. Aircraft Storage and Maintenance: Approximately 60% of the airport’s activity is devoted to aircraft maintenance. This service enables aircraft out of service or waiting to be resold or reused to receive necessary upkeep, with the option of returning to commercial service. Teruel has received large aircraft, including Boeing 747s, and is planning a new hangar for the Airbus A380, the world’s largest commercial aircraft.
2. Dismantling and Recycling: For aircraft reaching the end of their operational life, Teruel offers dismantling and recycling services. Each plane involves around 6,000 hours of work to disassemble and recover parts. Over 1,500 components and systems are extracted and certified for reuse in other aircraft. Parts such as engines, landing gear, brakes, and electronic systems are verified and recertified under European Aviation Safety Agency standards, receiving a certificate known as Form 1 before they can be sold on the market.
3. Material Recovery and Reuse: Teruel Airport has implemented an advanced recycling system that enables up to 92% of each aircraft’s weight to be recovered. This infrastructure allows metal parts from the fuselage to be separated, cut, and melted down into aluminium and other materials that are then used in various industries.
Since opening, Teruel Airport has created over 250 direct jobs, becoming a major economic hub in the region. Under the direction of Alejandro Ibrahim, an aeronautical engineer, Teruel aims to continue its growth and to become the leading European centre for aircraft storage and recycling, following the model of The Boneyard in Arizona.
The Future of Teruel Airport: Alejandro Ibrahim notes that with over 12,000 large aircraft currently in operation, the demand for dismantling and recycling services will rise in the next 20 years. This projection has driven Teruel to expand its capacity, including the construction of an additional hangar and the acquisition of state-of-the-art equipment to accelerate the recycling process.
Alongside other facilities worldwide, Teruel Airport is a prime example of a circular economy within aviation. By maximising the reuse of components and recycling materials, these boneyards help reduce the environmental impact of the aviation industry. Additionally, they make spare parts more accessible, enabling airlines to maintain their fleets more efficiently and sustainably.
In conclusion, aircraft boneyards, led by Teruel Airport in Europe, play a vital role in the life cycle of aircraft, providing a sustainable and economical solution as these giants of the sky reach the end of their journey.
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