Antonov Airlines’ commercial director Dmytro Prosvirin explains to Craig Waters, Editor of Air Cargo Management, how the Ukrainian freighter takes on heavy cargo shipments, referencing its recent project to deliver a power plant rotor from Atlanta, Georgia, US, to Nagoya, Japan.

Transporting heavy and oversized cargo by air is no small feat. It requires meticulous planning, specialised equipment and a dedicated team of experts to ensure the safe and timely delivery of these massive loads.

As a world leader in the field of project cargo air freight, Antonov Airlines recently faced a challenge which tested its logistical expertise that contributed to the success of transporting an enormous power plant rotor.

Meticulous planning

Almost every project transportation involving the AN-124-100(150) aircraft is unique according to the airline, and the load planning specialists at Antonov Airlines create individual plans for each mission. As Prosvirin explains: “They meticulously prepare for each transportation, considering the cargo’s characteristics and the customer’s requirements.

“The AN-124-100 Ruslan is a truly unique aircraft that has become indispensable for transporting super-heavy and oversized cargoes worldwide. What makes this aircraft stand out is its ability to ‘kneel’ by adjusting its specially designed landing gear to the ground angle. This feature, in combination with the nose cargo door, enables the loading of heavy single pieces, such as the massive rotor we recently transported.”

The mission to transport the rotor involved an elaborate process. Prosvirin continues: “A specially designed ramp, created by Antonov Airlines’ in-house engineers, was installed to facilitate the movement of the rotor from a truck to the aircraft. For safe transportation, the rotor was placed on a special frame, distributing the weight on the cargo floor of the aircraft. After handling the rotor on the ramp using an external crane, an onboard winch was used to pull the cargo into the aircraft. Once the rotor was secured in the cargo cabin, the technical crew dismantled the ramp system for future use at the destination airport.”

Specially designed ramp

One of the key components that contributed to the success of this mission was the specially designed ramp system. “Our engineers developed this unique overpass to allow the loading and unloading of single cargoes weighing up to 150 tonnes and measuring up to 4.10 metres in height,” explains Prosvirin. “What sets this ramp system apart is its adjustability, which depends on the length of the cargo piece, making the loading process safe and efficient.

“Moreover, this ramp system is not just robust but also easily transportable on board the aircraft. This autonomy means that it doesn’t require additional ground support, even in the most remote areas of the world. The ability to load tall cargoes with heights up to 4.27 metres using a low‑profile skate-type loading equipment further enhances the aircraft’s capabilities.”

Antonov Airlines’ AN-124-100 aircraft is equipped with onboard cranes that can handle cargo up to 30 tonnes directly from the platform of a truck or trailer. “This dual loading capability, from both the nose and tail, significantly saves time,” Prosvirin says. “Onboard winches, capable of handling monoloads weighing up to 150 tonnes, are another crucial part of the aircraft’s equipment, ideal for loading helicopters and airplanes.”

Meeting urgent time requirements with expertise and commitment

To meet urgent shipment times, Antonov Airlines employs several strategies and approaches. “We ensure that there is a ‘window’ between flights to allow the crew to rest according to their duty time,” explains Prosvirin. “In case of an urgent mission, a slip crew is sent for reinforcement, allowing them to work without delays. This flexibility and responsiveness enable us to perform urgent transportations and meet necessary time constraints.”

Antonov Airlines has an impressive track record in project cargo air freight, gained through years of experience and expertise. “Beyond just planning the loading and mooring of cargo, we carefully plan the optimal route and secure the necessary permits from countries along the way,” says Prosvirin. “We also provide essential aircraft services at airports such as fueling and de-icing, to ensure a seamless process.

“Despite the limited availability of AN-124-100 aircraft due to the Russian-Ukraine war, we remain the largest operator of the AN-124-100. We continue to fulfil our obligations to customers, making every effort to satisfy the demand for the transportation of super-heavy and oversized cargo. In a challenging landscape, our commitment to meeting critical delivery timelines shines through because ‘No other name carries more weight’.”

The successful transportation of heavy and oversized cargo by air requires a combination of engineering ingenuity, meticulous planning and a dedicated team. Antonov Airlines’ recent mission exemplifies these qualities, showcasing their ability to overcome unique challenges and deliver on their commitment to meet critical delivery timelines.

This feature was first published in Air Cargo Management – November/December 2023. To read the magazine in full, click here.