Modular Maintenance Platforms

The Challenge
In August 2024, the client faced significant operational challenges within their Maintenance, Repair, and Overhaul (MRO) facility due to limited hangar space. The primary issue was the lack of a secure and efficient method for storing aircraft seats after removal, leading to clutter, disrupted workflow, and encroachment on vital work zones.

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The Spark Ops Solution
Spark Ops Metalworks was contracted to address this critical space management problem. We developed a modular, multi-functional maintenance platform utilizing Infinite Shapes patented truss products. Each platform was engineered in-house using aluminum and steel components to provide:

• Elevated Storage:  Secure, dedicated storage for removed aircraft seats, keeping them off the hangar floor.
• Integrated Tool Storage:   Space for tools, toolboxes, and heavy-duty equipment with easy access for maintainers.
• Maximized Floor Space:  Clearance beneath the platform for access points and additional storage of specialty parts, toolboxes, or work carts.

Safety and Accessibility Features

• Stairs for stable access to work zones.
• Removable handrails at all access points and platform edges to prevent falls and enhance visibility.
• Heavy-duty bumpers to minimize impact risks to equipment.
• Kick plates on elevated edges to prevent dropped tools or parts.

These features created a safer, clutter-free workspace and streamlined movement within the hangar, supporting both OSHA compliance and maintenance efficiency.

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‍Deployment & Solution
A dedicated Spark Ops team, led by Founder Bryan Perl, completed the on-site installation in Macon. Three custom 40’ x 30’ structures were assembled in just two days using minimal tools, thanks to the modular and height-adjustable design. This rapid deployment showcased the platform's adaptability to varying aircraft sizes, hangar constraints, and tooling needs.