Chapman Freeborn Gets Creative for Flight to Rwanda

By Simon West

Air charter specialist Chapman Freeborn overcame multiple challenges including complex loading requirements and limited aircraft availability during a recent critical flight of oversized cargo from Abu Dhabi to Rwanda. Gerhard Coetzee, vice president of cargo for India, Middle East & Africa (IMEA), spoke to Breakbulk about the importance of creative problem-solving and his “pride” in successfully executing the demanding mission.

From Issue 1, 2025 of Breakbulk Magazine

(3-minute read)

Q: Can you tell us about the nature of the oversized components that were transported?

GC: The shipment of five outsized components was for a major gas infrastructure project in Rwanda and was carried out during planned maintenance at the plant to avoid a complete shutdown. The two larger pieces measured 12 meters long and weighed 5,000 kg. The smaller pieces weighed 1,500 kg apiece.

Q: What aircraft was used and why was it the best choice for transporting this cargo?

GC: An Antonov AN124 was used due to the outsized nature of the cargo, with the dimensions far exceeding normal wide-body freighters. Given the cargo’s sensitivity, the AN124 was the perfect choice for both its availability and ease of loading.

Q: Did the shipment require any specialized equipment during flights, such as cranes or custom loading systems? If so, what were they, and how were they deployed?

GC: Together with the shipper and manufacturer, Chapman Freeborn helped design a transport cradle to allow the safe transportation of the outsized manifold. During the loading and offloading at the airports, external cranes were used, and an inner-build crane was used to lift the cradles into the AN124.

Q: How long did the entire operation take, from planning to the cargo’s arrival at the project site in Rwanda?

GC: From the client’s initial request, this operation took two months in total. This included the lead time needed to design, manufacture and transport the bespoke cradle from the factory to the airport, and the time taken to secure vehicles and police permits for road transport, lining up with the aircraft’s departure time. The flight itself departed on time, taking seven hours from take-off to touchdown.

Q: What were the most significant challenges faced during this project? Were there any unexpected obstacles, and how did your project team overcome them?

GC: There were a number of obstacles from the very beginning of this project. For instance, the cargo was so oversized that it could not be loaded into any aircraft, including the AN124. Thinking outside the box, we designed and built a bespoke transport cradle to rotate the pieces and allow the cargo to be loaded onto the aircraft. We were then challenged by the availability of aircraft. The customer required two of the smaller components to be shipped last-minute ahead of the AN124’s schedule. Within the same day, Chapman Freeborn’s flight operations team were able to secure a Boeing 767 freighter to fly charter to the destination and the two pieces were modified to allow them to be loaded onto the aircraft.

Q: Is there a particular moment or aspect of this operation that you found especially rewarding?

GC: This was one of the most rewarding charters I have completed. Where others may have rejected this project because of the difficulties of loading these components, we worked with the customer and manufacturer to deliver the delicate cargo on time, safely and securely. The moment I saw the first piece being loaded onto the aircraft I felt real pride in my team.


Chapman Freeborn is an exhibitor at Breakbulk Americas.

TOP PHOTO: A constructed frame is deployed to offload cargo in Rwanda. Credit: Chapman Freeborn
SECOND: Gerhard Coetzee, vice president of cargo, IMEA. Credit: Chapman Freeborn