Technical |


Operations are the foundation of AirClad and all structures have been built to the highest standards to service these operations. This maximises the commercial viability of an investment and ultimately the longevity of our products. We run our own live events business which supports all projects and partnerships around the world. Our structures are designed to travel anywhere - as is our live event operation service.



The design and engineering undertaken is to ensure all the AirClad structures we supply have been built to the best standards possible to service their application. In turn this maximizes the commercial viability of any investment and ultimately the longevity of the AirClad products. 

We run our own live events business in the EU which supports all projects and partnerships around the world. Alongside support on a project by project basis, we are able to perform pre-event training and over the phone advice for all aspects of AirClad live events. The feedback from all live events with AirClad is core to our ongoing refinement. With annual AirClad conferences open to all we aim to always be ahead of operational needs in the future.


When the structures are shipped with transport racks we advise a fork lift to load and unload, but if not available unloading is also possible by hand.

The single story eXpo systems have been designed with minimal need of equipment. In most cases all work is undertaken at ground level. We recommend two sets of free standing 5m ladders and a 3m work height scaffold tower. XIP double height structures require a forklift and HIAB – as the structures are designed to be installed in a day this equipment can be hired short term. All Xpress systems will require a forklift to position.

If your project has special needs, such as being on a ski slope or in a desert, we will work with your team to accommodate your needs.


See the technical section of each size of AirClad for the recommended amount of crew for the set up and de-rig of each structure. AirClad’s live event company is able to be onsite with you to build the structure at every event worldwide (subject to availability), or alternatively for the first build to train and teach your crew in the set up and de-rig of the structure. 


AirClad is light enough to erect on a roof terrace with enough mass and rigidity to not slide. The weight of each structure will vary slightly, as a guide the single story weighs 65kg /m2 when installed and the two story 105kg/m2 . The weight of the goods on the transport stillage or pallets will be effected by how they are loaded together. All the designs we supply for loading will allow goods to be moved by hand or with fork lifts.

The AirClad weight is kept to a minimum with enough weight in the structures to allow for the them to be used, in most cases, without ballast.


The AirClad has a leveling system allowing for a run-off of 500mm, using rubber spreader plates. These are set on the ground underneath the flooring and spaced a maximum of 2m apart for lower run-offs and 1m for larger run-offs. If there is a slope of over 500mm, the packers need to be stabilised with cross bracing.

For smaller structures the run-off rarely goes above 500mm. With the 15m+ structures we recommend a site survey to assess the ground conditions and to prepare for larger packing needs prior to going live. In most cases the frame is built first and the levelling packers are added under the frame before laying the floor and adding the aircells. This allows all the heights and angles to be adjusted easily with maximum visibility before the structure is closed off. The AirClad can be used direct onto any staging system.

Ballast and Ground Fixing

In over 95% of applications, the AirClad structures do not require ballast or fixing. However, all AirClad have the facility to use ground fixings or add ballast within the under floor of the frame. With penetrative ground fixings we use Spira anchors at 600 or 900mm long or platypus anchors for deeper higher loads. Spira anchors must be a min 1m apart and the platypus min 2m apart. The AirClad floor system has tie points to connect it to load straps running between ground fixings or ballast.

Ballast is normally added as steel plates or concrete blocks due to their density. Sand bags or water ballast can also be used if it is a preferable local solution. The engineering documents cover all the parameters of these operations.

Packing Sizes and Transport Guidelines

eXpo touring events

Our eXpo systems have the option for transportation stillages for the frame, and flight cases for the glazing and air cells – ‘racking and packing’. This aids the logistics and security of the structures during transport and storage between events. When planning events please refer to the LOG Books for each structure for sizings. As a guide, each structure has a minimum of one flight case of 3m x 1.2m x 1.2m and the frame stillage will have dimensions of 2m x 1.25 x the width of the structure.

Our transport guidelines are that a 200m2 structure loads onto a 13m flatbed trailer. Smaller structures under 6m wide and 60m2 fit onto smaller transportions, subject to its length and weight capabilities. Structures over 60m2 are, in our experience, as efficient to ship on artic trucks as combining smaller transport. However, we note that this might be different from country to country – each project needs to evaluate its own logistics such as interior fit outs and other variables.

(n.b. the event touring equipment needs to be stored while the event is live – if this is a problem, we advise to operate a disposable stack and wrap system for transportation)

eXpo permanent installations

For permanent and long term installations we will palletise and wrap the structure in a safe and effective manner for initial shipping. The wrapping is all designed to be disposable.

Xpress touring events

The Xpress range has been designed as a fast, flat-packed hinge up system. All the elements are pre-built together prior to shipping so the onsite build times of the single module versions are complete in under 10 minutes. A forklift will be required on site to unload the structure.  The eXpress structures are designed to stack onto each other to a maximum of 8 units. There are 3 sizes: 2.5m, 4m and 6m. A flatbed trailer can take maximum 40 units of the 2.5m version, 24 units of the 4m version and 16 units of the 6m version. Due to the pre-assembly and its combined weight, a forklift will be required on site to unload these structures, unless they are disassembled and broken up in single parts.

Storage and Maintenance

Our Live event company offers a full storage and maintenance service. All goods should be stored long term in a secure dry place. If during a de rig structures become wet and dirty they can be packed away and opened later for cleaning. We recommend this is undertaken within 2 weeks of the event for white structures. Where possible ensure during the de rig that as much dirt and water is removed as possible. All the individual elements can be cleaned with a hot jet washers and Olionix cleaner.

In the main part all the elements of the frame and flooring will not be effected, but the Air Cells will need to be kept clean to maximise the look and life span of the product. The AirClad is an entirely modular constructed product and as such all the individual elements can be serviced and replaced in extreme cases. If you follow the general dos and don’t s from the LOG books we expect all AirClad to last for in excess of 5 years with 1 year manufacturing warranty

We offer extended warranty with all structures we tour and store and service. With an agreed amount of events a year we will offer free storage and servicing to give you full peace of mind and a turn key structure solution when ever you need it.


The twin wall nature of the AirClad offers a natural level of acoustic insulation. With the development of the Snoozy accommodation we have develop a removable acoustic liner which enhances the interior feel of the room and increase the sound absorption. This system can be used on the larger event structure or office pods where acoustics is important to the performance of the structure.


AirClad takes seriously the longevity and life expectancy of our AirClad strucutres. Each AirClad is viewed very much as an individual birth. Design and consideration has been taken to ensure all the materials, fabrics, fixtures, fittings, packing and structural details will perform way beyond the required projected timelines.

All AirClad structures come with a Log book and a comprehensive set of care and guidance notes on how to make the very best use of these structures to get the most out of them for the longest time. The LOG book is used as a core tool to advise and train staff who will be operating, touring, and storing the structures to ensure this happens and for sales teams to ensure that all clients have the best perspective of the system and its benefits to them.