Case Study
Hangar Doors
Project overview
Our client wanted an automation solution for hangar doors, with a desire to improve operational efficiency and safety. As specialists in automation, we had the perfect modern control system to suit their needs.
As with all our projects, we handled everything detail from start to finish, including the design, supply, and installation of advanced automation solutions for both the straight and curved door sections within their hangar.
About the client
The client operates a large-scale hangar facility requiring high-performance doors that can facilitate aircraft movement. Efficient access control and automation were key priorities to enhance operational workflow and improve safety within the hangar environment.
The Challenge
Issues with existing system
The client’s existing manually operated hangar doors presented several challenges:
· Inefficiencies in opening and closing operations, leading to increased turnaround times.
· High dependency on manual intervention, posing safety risks and operational delays.
· Lack of a standardised control system for both straight and curved door sections.
What were the customer’s objectives?
· Implement a fully automated system to make door operations smooth and seamless.
· Have an easy and problem-free integration of the automation system with both straight and curved doors.
· Improve safety levels with a controlled “hold to run” mechanism.
· Reduce the reliance on manual labour, boosting efficiency for users.
· Ensure compliance with health and safety regulations were prioritised.
What was the solution?
Here at Electro UK, we know how to tailor an automation system to suit any and every type of hangar door, whether curved, sliding, vertical or bi-fold, our specialist team use their extensive knowledge of automation solutions to find the perfect system. And in this project, we did exactly that, developing a tailored system to meet the client’s requirements. The project scope included:
Door configuration
Four straight doors combined into a single leaf, resulting in two bi-parting sections. This was alongside six curved doors combined into a single leaf, also resulting in two bi-parting sections.
Drive and power supply
Each door leaf was equipped with at least one drive unit. We installed eight high-level power supply points to make sure functionality remained strong and robust.
Control system
We installed a “Deadman” or “hold to run” operation mode, with push button controls tailored to the client’s requirements.
Project management and safety
We deployed our design and certification process, including operation and maintenance documentation, making sure the entire system met strict health and safety guidelines.
The installation process
Over a 32-week period, we carefully planned and executed the project, breaking it down into key phases:
Step 1: design stage (12 weeks)
This initial stage focused on detailed planning, system design, and certification.
Step 2: manufacture stage (12 weeks)
The production of automation components begins, tailored at every turn to the hangar’s specific requirements.
Step 3: installation stage (8 weeks)
We then began the on-site installation, integration, and system testing.
During the final installation phase, our team conducted a valuable 8-week training programme to make sure that the team knew how to operate and maintain the automated system.
Key challenges overcome
Integration with existing infrastructure
Despite the layers of complexity and requirements, the entire project was a success. The automation system was installed with minimal disruption to operations, which was great for their busy team.
Customised control mechanisms
The push button and “hold to run” system were designed to cater to the client’s specific safety requirements.
Health and safety compliance
We performed stringent risk assessments and factored in safety measures to be fully compliant with any regulations throughout the project lifecycle and beyond.
Enhanced efficiency
Automated doors significantly reduced aircraft movement times and improved workflow.
Improved safety
The “hold to run” control system minimised operational hazards and ensured safe door operation.
Reduced manual dependency
The advanced automation system removed the need for any extensive manual operation, which is a great way to reduce labour costs and potential delays.
Future-proofed system
The setup allows for future upgrades and integrations as needed.
Hear from our customers
“Working with Electro UK and their subcontractors, has been a seamless experience. The automation of our hangar doors has greatly improved our operational capabilities and efficiency. The project was managed professionally, and all safety standards were meticulously followed. We are extremely satisfied with the outcome.”
Upgrade your hangar doors
Electro UK successfully delivered a high-end, complex automation solution, boosting efficiency, safety, and compliance with industry standards.
No matter the hangar door type or volume, if you’re looking to automate or upgrade your hangar doors, our expert team is ready to assist.
Contact us today to discuss your hangar door automation requirements
