Megadoor, a subsidiary of Assa Abloy, the world’s largest door manufacturer, required a facility with a minimum 72 foot clear span area to fabricate its oversized flexible fabric doors. Typically used for aircraft hangars and other specialty military operations, the doors are comprised of aluminum and steel structural members supporting a heavy duty folding fabric.
Fabrication requires handling large elements efficiently using overhead cranes. Patrylo, Inc. adapted an existing 50,000 square foot facility by eliminating a column line within the building, creating an 80 foot clear span area for fabrication. This required the installation of new footings, columns and roof support girders. A new bridge crane was later installed and extended to an outside storage yard to allow efficient storage and retrieval of material components for the process. The facility also includes an oversized blasting and painting area. The overall project reduced the production area footprint and dramatically improved manufacturing efficiency.
Client: Megadoor/Cardo USA
Total Project Value: $2.5 M
Schedule: 4 months
“In our effort for capacity expansion, Patrylo’s design/build team offered us a renovation solution to an existing building. The challenge was to design and install a new structural support system complete with bridge crane support beams and track rails. This required moving column lines in addition to adding a new truss system spanning the entire building. There was also a portion of an existing end wall removed and crane rail installed thus allowing the installation of a Megadoor, which enables bridge crane access through the building.
We feel that Patrylo’s ability to make these renovations to an existing building offered us the best solution to expand capacity yet keep our investment cost much lower versus the cost of a new building.”
Assa Abloy Entrance Systems