Airbus A380 Baggage Handling Plant (2014)

Steel Flooring – Durbar Top
Location: Gatwick Airport South Terminal
Value: £375,000

Description

Our customer came to us with a specification for a precision galvanised steel floor comprising open steel flooring topped in 3mm Durbar plate.

The specification was rigorous in that panels were to be 2000mm x 1000mm and absolutely square.

These were to be fitted in-situ with a flatness tolerance of less than 1mm and a maximum 2mm gap between adjacent panels. Point load was set at 7.5kN

With a total area of 2200m² this was a critical part of the new South Terminal upgrade to accept the Airbus A380 and was time critical in order to meet planned airline services.

Gatwick Airport Steel Flooring - Baggage Handling Plant for the A380 Airbus

Prototype Panel

Manufacture

Our first step was to produce a panel that would meet the flatness requirement.

Although readily achievable in our works, subsequent HOT DIP GALVANISING would almost inevitably result in heat distortion.

We carried out numerous trials to get the welding pattern correct and finally on the 22nd trial succeeded in achieving satisfactory post galv flatness.

Gatwick Airport Steel Flooring - Baggage Handling Plant for the A380 Airbus

Prototype Panel

Load Testing

Concurrently we carried out load testing on the floor panels to ensure we would meet point load and deflection requirements and validate our calculations.

With 1,100 panels to manufacture we set up a dedicated manufacturing cell with its own Inspection and Test Plan (ITP).

The Floor was delivered on time and installed over a 6 week programme in the first half of 2014 with subsequent additional works added.

Gatwick Airport Steel Flooring - Baggage Handling Plant for the A380 Airbus

Distributed Load Testing at Lloyds British

Gatwick Airport Steel Flooring - Baggage Handling Plant for the A380 Airbus

Point Load Testing at Lloyds British

Gatwick Airport Steel Flooring - Baggage Handling Plant for the A380 Airbus

Laying Out Floor Panels

Gatwick Airport Steel Flooring - Baggage Handling Plant for the A380 Airbus

South Terminal Construction Site

Gatwick Airport Steel Flooring - Baggage Handling Plant for the A380 Airbus

Finished Floor Area – 2200m²

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