The Fabricated Systems group of Saint-Gobain Performance Plastics traces it's origin to a small group of engineers at Cornell Aeronautical Laboratory. They developed the first air-supported radome in response to the need to protect large surveillance radar antennas as used on the Early Warning System. The air-supported concept permitted minimal material thickness and avoided structural frame members which might interfere with the RF signal.
In 1956, these engineers envisioned the potential for both military and architectural applications utilizing high strength structural fabrics and formed a CAL spin-off, Birdair Structures Inc.
Walter Bird on first radome at CAL 1948
A major accomplishment in 1962 was the design and fabrication of the large, 210 ft. diameter radomes to protect the earth station antennas for the Telstar satellite communications system. These radomes are the largest ever constructed. This series of radomes (which ranged from 120 to 210 feet) introduced the principles of optimal pressurization system reliability, a concept which SGPPL continues to enhance.
The BTL horn antenna inside the Telstar radome
210 ft. Telstar Radome in Pleumeur-Bodou, France 1998
In 2002, the IEEE recognized Telstar and its associated ground stations as an electrical engineering historical milestone. The radome in France presently serves as a telecommunications museum which attracts over 100,000 visitors yearly. It is officially recognized by the French government as a historical structure. The photo links to a panoramic Quick Time view of the museum site. QuickTime is required to view the movie. You can download a free player from Apple.The panoramic view is courtesy of the Telecommunications museum in
Pleumeur-Bodou.
During the early 1970's, Birdair begin to utilize a new Teflon® -fiberglass material developed by Chemical Fabrics Corp (Chemfab®) for architectural applications as it offered excellent fire-resistance, high strength, and inherent long term service life under severe environmental conditions. It was later recognized that the utilization of PTFE Teflon®, with it's consistent low dielectric constant also provided superior RF characteristics. Taking advantage of Chemfab's unique weaving capabilities for the structural substrate combined with the ability to fuse the PTFE to that substrate resulted in a new series of radome materials trade named RAYDEL®. One of the initial applications was for the microwave level radome on the CN tower in Toronto, Canada. Designed and installed in 1973, the torroidal radome is 138 ft. in diameter and over 1100 feet above street level. The tower itself is the tallest free-standing structure in the world.
The CN Tower is a Toronto landmark
The Haj Terminal Jeddah, Saudi Arabia
In 1981, while working co-operatively on the 105 acre Haj airport terminal in Saudi Arabia, Chemfab® acquired Birdair to expand it's presence in design and fabrication. The combination of the resultant firm's unique material developments, design capabilities and fabrication capacity were applied not only to architectural structures and radomes, but to a multitude of special projects varying from chemical protection shelters and suits to custom designed antenna shelters. As the architectural field increasingly became extremely specialized, Chemfab® eventually decided to divest itself of that portion of the business (which continues under the Birdair name).
Some typical examples of the resultant capabilities include the application of specially pigmented RAYDEL® to produce such unique radomes as those provided to the Canadian DOD as replacements of rigid sandwich radomes used for precision aircraft landing control. In this application, not only was the superior RF performance (including inherent hydrophobicity and minimal water absorption) proven under comparative testing, but the coloration is a permanent feature never requiring repainting.
28 foot dia. Precision Approach Radomes are located throughout Canada
Likewise, a specially laminated PTFE coated Kevlar® (CHALLENGE®) utilizing Chemfab's proprietary film casting capabilities was developed in conjunction with the design of a series of tactical chemical-biological shelters for the US military. It is unique in its extreme chemical resistance, light weight and flexibility. It was then utilized in the manufacture of HAZMAT protective suits. This composite was further developed to obtain extremely high RF transparency. This version is presently produced as RAYDEL® SX-12 and utilized in both portable and permanent small radome applications. The composite is covered by patent
The CBPSS provides
frontline protection for
medical services.
The Challange 6400 HAZMAT suit is in accordance with NFPA 1991.
In the year 2000, Chemfab® was acquired by Saint-Gobain, a large global corporation renowned for its expertise in glass technology.
Saint-Gobain was created in 1665 as part of the plan devised by Louis XIV and Colbert to restore the French economy. Entrusted to private entrepreneurs, the company broke with the factory tradition by organizing glass production on an industrial basis. It provided the glass for the Hall of Mirrors at the Palace of Versailles and more recently for the pyramid entrance to the Louvre in Paris.
Designed by I.M.Pei, the Louvre pyramid entrance incorporates special glass manufactured by Saint-Gobain.
The Saint-Gobain Corporation is a world leader in each of its competencies. It is among the Global Five Hundred companies (155th in 2002) and is among the one hundred world leading industrial corporations. It consists of more than 1000 consolidated companies with industrial operations in 46 countries and employs about 172,000 people worldwide. In North America alone, it employs approximately 27,000 people and operates more than 200 plants. Fabricated Systems is part of the Performance Plastics Division located in Merrimack, NH.
Saint-Gobain Performance Plastics facility in Merrimack, NH
