Red Bull Air Race World Championship - Air Gates

Air Gates

The air gates are made up of one, two, or four pylons, each approximately 20 metres (66 ft) high, and spaced 10 to 15 metres (33 to 49 ft) apart depending on the gate.

The first prototype pylon was developed by Martin Jehart of Bellutti Protection Systems, an Austrian engineering firm specializing in the manufacturing of technical materials and tarpaulin. They initially used a latex balloon for crash tests and aerodynamic studies and after many tests and research settled on the use of a combination of different materials, the crucial component being spinnaker ripstop nylon, an extremely lightweight and flexible material used for making sails for boats. This would prove to be a breakthrough in the development of the Air Gates producing a pylon that would rip instantaneously when hit by a plane. Over 70 tests of the pylon were carried out on the ground using a car with a wing strapped on the roof before they were ready to undergo tests with a real plane. Eight different cars were used in these tests as well as a trailer and truck. Hungarian pilot, Peter Besenyei worked closely with the team and attempted the first deliberate pylon hit in early 2003 with positive results. The first Air Gates, which were cylindrical, were finally ready to be used at the very first Red Bull Air Races held in Austria and Hungary later that year.

The Air Gates play a vital role in the Red Bull Air Race, but must also fulfill complex and contradictory demands. They have to be delicate enough to burst apart the instant they are touched by an aircraft and sturdy enough to remain stationary in all weather conditions, including stormy weather and strong winds. The early cylindrical pylons fulfilled the first criterion but proved to be too unstable in the wind.

The answer came in 2004 with the cone design. These Air Gates measure 5 metres (16 ft) across the base and .75 metres (2.5 ft) at their tip. Inside the Air Gate a relatively high, and carefully monitored, pressure level is maintained with the use of powerful electrical, petrol-powered blowers that help keep the Air Gates steady even in windy conditions. Over the years the Air Gate design has developed and improved and today's Air Gates can withstand wind speeds of up to 60 km/h (37 mph) without being blown over. Their stability is further reinforced with 12 ground attachments, each strong enough to hold 1,200 kilograms (2,600 lb). For races over water, the Air Gates are secured to a floating barge which has stability anchors.

Unlike early models, the current structures are made up of six sections attached together by zippers and Velcro to allow quick replacement if damaged by a plane. Prior to May 2008, the races had used more than eight tons of fabric for the various pylons, and the average life of each pylon was 15 races. Thirty-five pylons are transported to each race, and at each race's completion, the pylons are sent to Innsbruck, Austria to be repaired.

If a pylon is hit by the plane, it is designed to break apart, preventing it from harming the plane and pilot. The damaged parts of the pylon are replaced by course personnel nicknamed "Air Gators". It usually takes a few minutes to replace a pylon. The record for the setup of a replacement pylon is 1 minute 30 seconds, set in 2007.