Industrial Doors
Industrial Door Engineering Installs Bespoke Wind Resistant Roller Shutter Doors For Holyhead Marine Services
Industrial Door Engineering (IDE) recently completed a specialist installation of roller shutter doors for Holyhead Marine Services to resolve long-standing operational issues at their shipyard.
As a specialist in the construction, refit and repair of aluminium, steel and GRP boats, Holyhead Marine Services operates in a demanding coastal environment where a standard galvanised roller shutter had proved insufficient. For several years, high winds frequently caused the existing roller shutter to blow in, resulting in structural damage and interruptions to production schedules.
Following a site visit by the IDE team to evaluate these specific environmental challenges, the client visited the IDE manufacturing facility in Northwich, Cheshire. Based on this consultation, the decision was made to replace the failing units with bespoke IDE insulated foam filled shutters designed for enhanced thermal performance and durability.
IDE manufactured and installed four large insulated roller shutter doors, bespoke to the shipyard’s unique structural demands. To meet the client’s aesthetic requirements, the units were finished in a Solent Blue laminate. The shutter curtain itself is constructed from 95mm deep insulated steel laths, injected with CFC-free polyurethane foam. This profile features a high-quality PVC laminate finish on both sides as standard, providing the anti-scratch properties and durability necessary for a busy shipyard environment.
The scale of the installation was significant, featuring openings up to 7800mm wide and 9800mm high. Since these dimensions exceed standard industry sizes for this profile, the manufacturing process focused on ensuring structural integrity at height. To provide additional rigidity across these wide spans, the outer surfaces incorporate three grooves for increased strength. This design contributes to a thermal performance of 3.3 W/m² K and an acoustic rating of 22 dB, whilst ensuring the curtain remains stable under the significant wind loads encountered at the Holyhead site.
To further mitigate the issues caused by the coastal location, the design included vertical brush seals within the guides to manage air permeability and reduce operational noise.
“Installing doors of this magnitude in a coastal environment requires a shift from standard designs to bespoke engineering,” says Jeff Baldwin at Industrial Door Engineering. “Our priority was to solve the recurring failure cycle the client had endured for years. By integrating our 250mm wind locked guide system, we’ve provided the structural rigidity necessary to withstand high velocity winds and prevented the production delays that previously impacted the shipyard.”
Safety was a primary consideration in the drive system design. Each unit was fitted with a high standard drive motor and a built-in safety brake system designed to prevent the door curtain from falling
in the event of a mechanical failure. The
entire installation was manufactured and installed in accordance with BS EN 13241-1:2003 + A2:2016 and BS EN 12604:2017.
To maintain site security throughout the installation, the team followed a phased approach, removing each
existing standard galvanised door and
replacing it immediately with a new insulated unit. This sequential approach ensured that each opening was fully secured by the end of every shift, maintaining site integrity throughout the five day project.
Upon completion, the doors were demonstrated to the client. The new solution has remained rigid during high coastal winds, addressing the primary cause of previous operational downtime. The client expressed satisfaction with the product performance and noted the increased stability of the IDE roller shutter doors compared to the previous standard installations.
For more information please visit:
https://industrial-door-eng.co.uk/
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