PREPARED & ISSUED BY
Technocrats Kohlhauer Infrastructure Pvt. Ltd.
Corporate Projects & Aviation Infrastructure Division
41.45 m
Clear Opening Width
12.86 m
Clear Opening Height
296 km/h
Cyclonic Wind Design
4
Motorized Sliding Leaves
Project Case Study
CLIENT
Airports Authority of India (AAI)
LOCATION
Biju Patnaik Int'l Airport (Bhubaneswar, Odisha)
SCOPE
Turnkey EPC: Design, Steel Structure, Civil Slab, Automation, Testing & Commissioning
WIND LOAD RATING
296 km/h (82.2 m/s) Cyclonic Design
PROOF CHECKING
Vetted & Approved by IIT Bhubaneswar
QUALITY & TESTING
Bhubaneswar Test House (ISO 9001:2015)
EXECUTING AGENCY
Technocrats Security Systems / TKIPL
PROJECT AUTHORITY REF
AAI/BBSR/Engg.(E)/Sliding Gate/2022-23/1939
1. Key Highlights & Project Outcomes
01
Turnkey Single-Source Delivery
In-house engineering, structural analysis, precision modular fabrication, civil track execution, and automation commissioning with complete accountability.
02
High Cyclone Resilience
Robust structural engineering successfully protects vital aircraft assets against extreme weather disturbances in coastal Odisha.
03
Proven Drive Reliability
SEW-Eurodrive helical-bevel motors and hardened steel wheel assemblies provide smooth, low-maintenance, and continuous duty-cycle performance.
04
Statutory & Institutional Compliance
Seamless multi-agency coordination with AAI, IIT Bhubaneswar, and state testing authorities ensuring complete technical and regulatory clearance.
2. Executive Summary & Operational Context
Technocrats Kohlhauer Infrastructure Pvt. Ltd. (TKIPL) / Technocrats Security Systems Pvt. Ltd. successfully executed the turnkey engineering, manufacturing, civil infrastructure, and motorized installation of a heavy-duty sliding aircraft hangar door for the Airports Authority of India (AAI) at Biju Patnaik International Airport (Bhubaneswar, Odisha).
Located in a high-risk tropical cyclonic corridor along India's eastern seaboard, the hangar door required specialized engineering capable of withstanding severe cyclonic wind speeds up to 296 km/h (82.2 m/s). The complete structural framing, foundation, and automation systems were independently proof-checked and vetted by the School of Infrastructure, IIT Bhubaneswar and validated via certified laboratory testing.
3. Technical Specifications & Dimensional Parameters
| Parameter | Technical Specification & Dimension | Functional Benchmark / Engineering Detail |
|---|---|---|
| Clear Opening Size | 41,450 mm (Width) × 12,865 mm (Clear Height) | Engineered for unobstructed aircraft entry and exit |
| Overall Structural Envelope | 44,000 mm (Width) × 13,400 mm (Total Height) | Full superstructure enclosing gantry and guide frames |
| Total Track / Travel Length | 53,800 mm (includes 9,000 mm side parking pocket) | Enables 100% full-span clear operational opening |
| Leaf Configuration | 4 Multi-Leaf Telescopic Bottom-Supported Sliding Panels | Individual 4-track unidirectional sliding arrangement |
| Individual Leaf Dimensions | 11,350 mm (Width) × 12,500 mm (Height) each | Composed of 2 modular half-leaves (5,675 × 12,500 mm) |
| Exterior Cladding | Heavy-duty pre-coated corrugated steel profile sheets | Corrosion-resistant weather and dust barrier |
4. Structural Framing & Civil Track Infrastructure
Structural Steel Framing:
Primary Chassis & Columns
Jindal Universal Beams (UB 356×171×51 and UB 356×171×45) engineered for optimal rigidity and high bending resistance under lateral gust pressures.
Overhead Guide Gantry
UB 203×133×30 top guide support beam and top roller guides featuring 4 heavy-duty dual-flanged guide rollers per leaf to safely transfer wind reactions without binding.
Purlins & Skirting
Structural Square Hollow Sections (SHS 100×100×2.5 mm purlins and SHS 50×50×2.5 mm skirting) connected with 10 mm thick cleats and M10/M20 Grade 8.8 structural fasteners.
Civil Track & Foundation Substructure:
RCC Foundation Slab
54.30 m (L) × 4.23–4.40 m (W) × 0.35 m (D) heavy reinforced foundation slab cast on a 75 mm Plain Cement Concrete (PCC 1:4:8) sub-base over compacted sand.
High-Yield Reinforcement
Fe500D / Fe-550 HYSD reinforcement configured in a double-layer mat (Double Jali: Ø12 mm @ 100–150 mm C/C and Ø16 mm @ 150 mm C/C) to withstand dynamic wheel loads.
Track Integration
Embedded heavy-duty CR-50 crane rails precisely aligned to ensure smooth bottom-supported travel.
5. Electro-Mechanical Drive Automation & Safety Systems
SEW-Eurodrive Helical-Bevel Geared Motors:
- Model: K77 DIBE90M4 / BE2B / HR (Mounting M4A)
- German-engineered high-torque geared drive units
- 1 dedicated motor unit per leaf (4 motorized leaves total)
- Integrated fail-safe electromagnetic brake & manual release override
- Precision Ø350 mm forged steel drive & idler wheel assemblies
Power Distribution & Operational Safety:
- Enclosed multi-pole copper conductor busbar rail system
- Central 3-Phase PLC/relay control panel for synchronized opening
- Audio-visual safety indicators (synchronized strobe lights & sirens)
- Heavy-duty elastomeric rubber end-stop buffers on all travel extremes
- Multi-lip heavy rubber perimeter weather and dust seals
6. Structural Analysis & Extreme Cyclonic Load Design
Finite Element structural modeling was conducted on STAAD.Pro in conformance with IS 800:2007 (Limit State Design) and IS 875 (Part 3): 2015 (Design Wind Loads):
| Analysis Parameter | Calculated Value / Design Limit | Code Reference & Safety Compliance |
|---|---|---|
| Basic Design Wind Speed (Vz) | 296 km/h (82.2 m/s) | IS 875 (Part 3): 2015 (Extreme coastal cyclonic zone) |
| Basic Wind Pressure (Pz) | Pz = 0.6 × (82.2)² = 4,054 N/m² (4.05 kN/m²) | Dynamic wind surface pressure |
| Design Wind Pressure (Pd) | Pd = kd × ka × kc × Pz = 2,918 N/m² (2.92 kN/m²) | Factors: kd=1.0, ka=0.8 (area ≥ 100m²), kc=0.9 |
| Net Design Force (F) | F = (Cpe + Cpi) × Pd = 2.628 kN/m² | Cpe=0.7, Cpi=0.2 on building envelope |
| Permissible Deflection (H/150) | Max Allowable: 12,850 / 150 = 85.66 mm | Table 6, IS 800:2007 structural standard |
| Actual Max Deflection | 77.65 mm (PASS) | 8.01 mm buffer below permissible threshold |
| Critical Member Stress Ratio | 0.741 (PASS) (Beam UB 356×171×51) | Sec. 8.2.1.2 IS 800:2007 (Utilization < 1.0) |
7. Independent Third-Party Proof Checking & Certifications
| Certification | Parameter | Details |
|---|---|---|
| IIT Bhubaneswar proof checking | Authority | School of Infrastructure, IIT Bhubaneswar |
| Lead Faculty | Dr. Sumanta Haldar (Associate Professor) | |
| Official Endorsement | 08.09.2022 | |
| Scope | Complete design calculation and structural drawing verification (Drawing TSS/BBSR/HD/01). Certified and stamped for 296 km/h wind speed execution. | |
| Concrete compressive testing (IS 456) | Laboratory | Bhubaneswar Test House (Govt. Approved / ISO 9001) |
| Project Ref | AAI/BBSR/Engg.(E)/Sliding Gate/2022-23/1939 | |
| Results | 7-Day Strength: 24.00 N/mm² (Min. Req: 20.00 N/mm²) · 28-Day Strength: 34.00 N/mm² (Min. Req: 30.00 N/mm² for M-30) | |
| Verdict | Fully compliant with AAI technical parameters. |
VERIFIED & VALIDATED FOR
Airports Authority of India (AAI)
Biju Patnaik International Airport, Bhubaneswar