Capability enhancement
Marshall is proud to work with global OEMs and fleet operators to extend the mission capability and longevity of their aircraft.
Whether we are bringing a legacy C-130 Hercules into compliance with international aviation regulations after 60 years in service or increasing the operating range of Boeing’s P-8A Poseidon patrol aircraft, capability enhancement is at the core of what Marshall does.
Modernisation programmes
The Lockheed Martin C-130 Hercules remains the global tactical airlift platform of choice, having been in continuous production for longer than any other military aircraft in history. The airframe’s unmatched longevity is one of its hallmarks, with some aircraft built over 60 years ago still in operation today.
While operating a fleet of legacy C-130 aircraft is an extremely viable and cost-effective way to maintain tactical capability, maximising the lifespan of this legendary aircraft will require regular upgrades to ensure continued airworthiness and compliance with evolving aerospace regulations.
Marshall has an exceptional track record in delivering multi-year upgrade programmes designed to ensure that any C-130 aircraft can continue to support tactical operations around the world for many decades to come.
Structural modernisation
Having replaced almost every major structural component on the C-130 without OEM involvement from Lockheed Martin, we have developed bespoke jacking and trestling instructions and equipment to allow significant structural items to be refurbished and replaced efficiently and to the highest standards. For this reason, we occupy a leading position in the non-standard repair and replacement market.
Case study - fuselage stretch programme
Over the course of three years, Marshall performed an unprecedented fuselage stretch programme for the UK’s Royal Air Force (RAF). By adding two new fuselage sections to 29 C-130 aircraft, we were able to extend their total length by 15 feet and increase cargo compartment volume by roughly a third.
The OEM-supplied parts comprised a 100 inch plug for the front section of the aircraft, and an 80 inch section between the wing and the para troop doors. In addition to fitting the new sections into place, Marshall fully adapted the aircraft’s systems and wiring.
These aircraft flew for years and completed many vital missions, ferrying supplies and undertaking medevac sorties, among other duties.
Centre wing box replacement
The centre wing box is a fatigue-life item that will require replacement to ensure the continued airworthiness of the aircraft - no major C-130 structural component attracts such a high operational load.
Marshall is the world’s only maintenance, repair and overhaul organisation to have performed centre wing box replacement on both C-130K and C-130J aircraft - an exceptionally complex modification that can only be undertaken with dedicated facilities, tooling and knowhow.
Once the existing centre wing unit is removed, we install a zero life centre wing box kit - manufactured by Lockheed Martin - that delivers significant durability enhancements and provides service life extension for the centre wing box by up to three times longer than the original units.
Working in collaboration with Lockheed Martin, Marshall performs centre wing box replacement in a specially refurbished state-of-the-art hangar, harnessing our extensive C-130 deep maintenance and modification expertise, along with the use of LEAN manufacturing processes, to remove and reinstall the new centre wing box as quickly and efficiently as possible.
Centre wing box replacement
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Other major structural repairs, replacements and refurbishments we perform include:
- Flight deck window doubler repairs and replacements
- Engine truss mount repair and replacement (including force-mate bushing installation)
- Inner and outer wing attachment (rainbow) fitting replacements
- MLG beams, fuselage beam caps and belly skin replacements
- Sloping longeron (FS737-FS1041), upper BL61 and BL20 longeron repairs and replacements
- Centre wing drag angles, chine angle and chine cap repair and replacement
Avionics modernisation
Marshall has decades of expertise in avionics modernisation, overseeing comprehensive programmes from start to finish including design, installation, commissioning and testing.
Our teams can perform avionics studies on each C-130 fleet, creating bespoke avionic modernisation packages to address obsolescence, provide operational capability enhancements and ensure compliance with international aviation regulations. Our experienced test pilots work alongside a dedicated engineering team to evaluate the suitability and usability of all upgrades.
Case Study – Royal Netherlands Air Force (RNLAF) Cockpit Upgrade and Cabin Safety Improvement
As part of one of Marshall’s most extensive and complex engineering projects to date, we undertook a comprehensive avionics upgrade for four legacy RNLAF aircraft, comprising a cockpit upgrade programme (CUP) and a cabin safety improvement programme (CSIMP).
To learn more about these broader projects and our comprehensive overhaul work for RNLAF, read our case study here.
Avionics modernisations we provide
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Communications systems
- UHF comms including secure and encryption
- VHF comms and datalink
- HF comms
- Intercom systems including wireless intercoms
- Satellite communication (SATCOM)
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Operational enhancements
- Enhanced vision systems
- Electro-optic turrets
- Night vision imaging systems (flight deck, cargo bay and external lighting)
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Navigation systems
- Standby instrumentation
- Heading reference
- Electronic flight bags
- Flight management systems
- Digital maps
- Primary and navigation display systems
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Surveillance systems
- Traffic collision avoidance systems (TCAS)
- Automatic dependent surveillance-broadcast (ADS-B) out
- Weather radar
- Mode 5 identification friend or foe (IFF)
- Cockpit voice recorder and digital flight data recorder (CVR/DFDR)
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Aircraft and crew protection
- Chaff and flare
- Radar warning receivers (RWR)
- Missile approach warning system (MAWS)
- Directional infrared countermeasures (DIRCM)
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Command and control/ISR
- Tactical data link (Link 16)
In addition to conducting avionics modernisation programmes ourselves, we are able to provide third party organisations located near our customers with service bulletin kits containing all parts, components and instructions needed to perform the same modifications, while also training local technicians on the modification implementation process.
Learn more about our aviation skills and training offering.
Adaptable Role-fit Capability (ARC)
Marshall’s Adaptable Role-fit Capability (ARC) product family includes a range of platform-agnostic systems designed to rapidly enhance an aircraft’s capability within hours, enabling fleet operators to flexibly and efficiently reposition their aircraft for different types of mission - from cargo transport to medical evacuation and even intelligence, surveillance and reconnaissance (ISR).
Radar
Marshall ARC Radar is a modular sensor suite that allows operators of tactical transport aircraft to quickly and temporarily outfit an aircraft for intelligence, surveillance and reconnaissance (ISR) missions.
As the first of several products within the Marshall Adaptable Role-fit Capability (ARC) family, ARC Radar is a palletised solution with no permanent integration and no modifications required, utilising only existing aircraft power outlets.
The system’s potential applications are remarkably broad, ranging from military ISR land, sea or air missions to applied civilian operations such as search and rescue, humanitarian support, and disaster relief. Despite being fitted temporarily, the Osprey 30 radar suite maintains full performance during operation.
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ARC-Radar core system
- Mission Management System (MMS)
- AESA Multi-mode Leonardo Osprey 30 Radar
- Compatible with a range of permanent and role fit satcom solutions
- 463L master pallet system compatible with existing cargo handling systems
- 2 Panel radar solution with unrestrictive field of view
- Proven market leading equipment packaged in a unique and innovative solution
- Discrete conformal radome
- No permanent modification to the aircraft required and no reduction of aircraft performance
- Expandable modular sensor functions that can be upgraded at any time to integrate into the core system by design
View the Marshall ARC-Radar spec sheet
Aeromedical evacuation system (AMES)
Marshall ARC AMES enables fleet operators to outfit aircraft for tactical and strategic medical evacuation missions on demand, giving medium- and high-dependency patients the optimum chance of survival during air transport.
The palletised system can be rapidly installed and removed, requiring no modifications to the aircraft and utilising the existing aircraft power supply.
AMES can be configured to specific operational needs, while its modular design allows multiple modules to be connected to support additional patients.
Multiplatform cargo winch
Marshall’s roll-on, roll-off multiplatform cargo winch supports the loading of heavy objects - particularly in remote locations where ground support equipment is unavailable.
The system can be installed without any modifications, and makes use of existing electrical outlets for power, meaning it can easily be transferred as needed between multiple aircraft within a single fleet.
View the Multiplatform Cargo Winch spec sheet
Lightweight armour
Thanks to an exclusive agreement with QinetiQ, Marshall is the first company to certify and deliver the latest generation of lightweight armour (LAST Armor® LWA) for the C-130 Hercules, giving operators around the world confidence that their crews are protected against small arms fire in hostile environments.
The armour is manufactured from high tenacity polyethylene, making it extremely robust and remarkably light. It can be quickly and easily installed during scheduled maintenance or as a standalone activity, thus ensuring optimum aircraft mission availability.
C-130 Hercules lightweight armour
Operating range extension
Marshall has decades of expertise in developing and providing solutions that extend the operating range of aircraft - whether through the production of auxiliary fuel tanks or the installation probes for aerial refuelling.
Fuel tanks
For over four decades, Marshall has produced auxiliary fuel tanks that have been retrofitted to 10 commercial and military aircraft types across five major OEMs including Airbus, Bombardier and Boeing. We offer a safe, reliable and certified solution needed to meet range-extension requirements, today and in the future.
We have been working extensively with Boeing since 1997, initially providing auxiliary fuel tanks for commercial airliner variants such as the 747-400ER and 777-220LR Worldliner. Since 2009, we have been Boeing’s exclusive supplier of auxiliary fuel tanks for the globally successful P-8 Poseidon maritime patrol aircraft, end customers for which include the United Kingdom, United states, Australia, India, New Zealand and Norway.
With over 1,100 tanks produced to date, we have achieved an uninterrupted 100% on-time delivery record for over a decade, earning Boeing’s coveted Blue Supplier status.
The auxiliary fuel tanks extend the flight range of the aircraft and allow for additional time on station. Marshall supplies the tanks in ship-sets of six, along with a number of components.
The certified dual-wall aluminium honeycomb structure we use for our P-8A tanks is a cost-effective solution that maximises strength and reliability while also providing very competitive weight-to-fuel volume performance. They offer a 15% increase in fuel volume compared to conventional bladder solutions, and require less frequent maintenance.
We are constantly embedding continuous improvement into our processes and using of new materials such as composite solutions to expand the capabilities of our fuel tanks and systems.
Aerial refuelling probes
Marshall has extensive experience providing fixed-mast receiver probes for aerial refuelling on a variety of civil and military aircraft types, including the Lockheed L1011 Tristar, Embraer 145, and Lockheed Martin C-130K Mk1/Mk3 and C-130J. These are simple, reliable additions to the aircraft with minimal maintenance requirements.
As the sole supplier of aerial refuelling probes for the C-130J, we carry out design, analysis and manufacturing in house, delivering completed probes - along with in-fuselage centre-wing connection kits - to Lockheed Martin’s final assembly line in Marietta. These probes are already installed on the Italian, Indian and Australian C-130J fleets, and can be supported on all non-US operated C-130J aircraft.
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Aerial refuelling probe modifications we offer:
- Refuelling MA-2 nozzle
- Refuelling mast
- Inner refuel line
- Purge line
- Mass balance installation
- Weak link (for safety in case of separation failure)
- Breakaway/shut-off valve
- Metal or composite fairing manufacture and integration
- Structural mounting and fuselage reinforcement
- Nozzle illumination - installation of day- and night-compatible lighting
- Flame arrestor/isolator for lightning protection
- Fuel and moisture drainage
- Cockpit panel modification to accommodate aerial refuelling operation
- Avionic and control logic integration
- In-fuselage dual-wall system installation
We can also design aerial refuelling probes to be removable, reducing drag and lowering the weight penalty when they are not needed.
Through-life support
We manage the global supply chain for our products, leveraging our long-term relationships with equipment and material OEMs to provide the required expertise at the right time in the right place.
Our supply chain processes are audited to AS9100 standard and our extensive knowledge of export regulations, including ITAR, helps ensure we maintain a compliant, sustainable and socially responsible procurement process.
We offer extensive warehouse and distribution services, including the capability to hold inventory in our fully bonded and climate-controlled storage space. Our warehouse team undertake all goods receipts, inspection, storage and handling of parts, including dangerous goods.
Skills and training
We are proud of our award-winning apprenticeship scheme that has enabled more than 21,000 people to launch their careers over the years, and are committed to leading the industry in addressing the severe global skills shortage.
Building on the strength of our reputation in this area, our dedicated education and training arm, Marshall Skills Academy, delivers apprenticeships for businesses across the defence and engineering sectors as well as in-house for Marshall. In addition to apprenticeships, we provide a comprehensive range of technical, regulatory and health and safety training programmes to civil and military customers.
To learn more about our skills and training offering.