Westgate Global keeps Heathrow hangar weather-protected during door replacement

Protecting operations during door replacement

Hangars at Heathrow play a critical role in maintaining safe, reliable flight operations. They provide specialist, controlled environments for Maintenance, Repair, and Overhaul (MRO) services, allowing aircraft servicing to continue without weather disruption and supporting round-the-clock operational demands. 

The project required Mace to remove and replace two giant hangar doors that had been in place for more than 50 years. To maintain operational continuity, the hangar and its contents needed to remain protected and fully functional throughout the works. 

Standing more than 311ft wide and 88ft tall, each door needed to be replaced individually. To achieve this, the solution must be flexible and durable enough to be relocated from one side of the hangar to the other. The screen had to serve as an external weather barrier while also providing Mace with the space and access they needed for the works to proceed safely and efficiently. To minimise downtime and maximise usable floor space, any screening also needed to be quick to install and have a small footprint.  

Flexiscreen delivers weatherproof seal

Following a detailed consultation and site survey, Westgate Global installed Flexiscreen. The suspended modular screening system is proven to shield open buildings from the weather, regulate temperature, and prevent dust from spreading. 

With no need for a supporting structure, Flexiscreen was fixed directly to the main structural door girder, installed at a 70-degree angle, then splayed out at the base. This design created an 26ft working zone, allowing Mace to safely operate the crane needed to remove the huge hangar door. Once the door was removed, the screen acted as the primary weather barrier until the new door was installed.  

Westgate Global’s Structural Engineer designed the installation to meet wind load requirements, incorporating wind load strap anchor points at 1300 mm intervals, with 87 ratchet fixing points installed to a 0.006 tolerance over 311ft. To maintain compliance with UK Temporary Works procedures, the team returned to the site every 12 weeks to retest tautness and verify ongoing performance against wind-load calculations. 

Above the Flexiscreen, the team used an additional 3.5-metre screen to create an enclosed, high-level walkway. Eight emergency exits with zip openings were used to provide safe access to service platforms and ensure that maintenance activity could continue throughout the works. In addition, two steel pedestrian doors were also installed, enabling movement through the screened area without compromising protection. 

Crucially, once the first hangar door was removed and replaced, the Flexiscreen solution was relocated to the other side of the hangar. This ensured that work could continue without delay or additional costs.  

Unlike traditional scaffold sheeting, Flexiscreen provided Heathrow with a robust solution specifically engineered for high-stakes environments. With an air- and dust-tight seal of more than 99%, the screening provided a reliable barrier that fit neatly around protrusions and service access points.  

Learn more about Flexiscreen