Why access hatches are critical in airport environments
Airports present some of the most challenging conditions for roof access design. Unlike standard commercial buildings, access systems must account for:
- High live loads from maintenance equipment, trolleys and wheeled plant
- Fire compartmentation requirements between terminal zones and plant areas
- Extreme durability expectations due to constant operational use
- Strict security and access control protocols
- Complex roof build ups incorporating finishes, membranes and recessed infills
- Zero tolerance for water ingress or operational failure
These factors mean standard off the shelf access products are rarely suitable. Each hatch must be engineered as part of the building system rather than treated as a simple opening.
Client requirements and specification drivers
The Abu Dhabi Airport specification called for a combination of internal and external access hatches, each tailored to its location and function.
Key performance requirements included:
- Grade 316 stainless steel construction for corrosion resistance and longevity
- High load capacity, designed for slow moving wheeled loads up to 81 kN
- Fire rated access hatches, including FR120 and 2 hour fire resistance where required
- Recessed lids to accept architectural finishes and resin infills
- Controlled opening mechanisms suitable for frequent maintenance use
- Compatibility with complex roof finishes, including flexible resin systems
In addition, all units needed to be manufactured with consistent tolerances to suit predefined structural openings and coordinated across multiple shipment phases.
The Surespan solution
Surespan supplied a series of bespoke HIAC access hatches and thermally broken electrically operated roof hatches, manufactured in the UK and shipped to site in phased consignments.
Access hatch specification
Across the project, the supplied units included:
- HIAC external access hatches in Grade 316 stainless steel
- FR120 fire rated access hatches, tested for 2 hour fire resistance where specified
- Typical hatch sizes included 1200 x 750mm, 1000 x 750mm and 750 x 750mm, matched to structural openings
- Recessed lids designed to accept 40mm recessed build up plus 10mm flexible resin, ensuring flush integration with surrounding finishes
- Satin polished top trims to exposed stainless steel elements
- Slow moving wheeled load rating of 81 kN, suitable for airport maintenance traffic
For roof locations requiring powered operation and fire performance, Surespan also supplied SRHE thermally broken electrically operated roof hatches, complete with:
- 24V DC electric actuators
- Manual hold open stays for maintenance
- Integrated limit switches
- Fire resistance to EN 1643-1
- Insulated construction to support thermal performance expectations
Manufacturing, coordination and approvals
Given the scale and sensitivity of the project, Surespan followed a structured approval and coordination process:
- Detailed review of access schedules and opening sizes
- Production of general arrangement and section drawings for each hatch type
- Coordination of recessed depths to suit resin and architectural finishes
- Approval of fire rated and load bearing performance prior to manufacture
- Phased manufacturing and crating, aligned with site logistics and programme
Each hatch was supplied fully assembled and labelled to ensure correct placement on arrival at site, reducing installation risk in a live airport environment.
Logistics and delivery
Due to the number of units and the weight of the products, deliveries were split across multiple consignments. Crates were sized to suit handling constraints while protecting finished stainless steel surfaces during international transport.
All products were manufactured in the UK and shipped to the UAE in accordance with project specific documentation and certification requirements.
Outcome
- The completed access solution provided Abu Dhabi Airport with:
- Safe and reliable roof access for ongoing maintenance and inspection
- High load bearing performance, supporting wheeled maintenance equipment
- Fire compartment integrity where required across terminal zones
- Flush architectural integration, maintaining roof aesthetics and drainage
- Long term durability suitable for a high use transport environment
The project demonstrates Surespan’s capability to deliver complex, multi specification access solutions for major aviation infrastructure, where performance, safety and reliability are non negotiable.
Products featured
- HIAC Grade 316 Stainless Steel Access Hatches
- FR120 Fire Rated Access Hatches
- SRHE Thermally Broken Electrically Operated Roof Hatches
