5 Crucial Factors in Airport Door Design: Why Middle Eastern Airports Choose Honeycomb Over Solid Core

5 Crucial Factors in Airport Door Design: Why Middle Eastern Airports Choose Honeycomb Over Solid Core

When designing doors for modern airports, engineers face a critical choice: traditional solid core or advanced honeycomb construction? Nowhere is this decision more challenging than in the Middle East, where lightweight solutions must meet extreme fire safety requirements. Having supplied doors to 12 international airports in the region, we reveal why aluminum honeycomb cores with special fire coatings are becoming the gold standard.

1. The Weight Dilemma: Honeycomb vs Solid Core

✔ Solid Core (Traditional Choice):

• 45-65kg per door panel

• Solid wood or particleboard filling

• Excellent sound insulation

✔ Honeycomb (Modern Solution):

• 18-25kg per panel (60% lighter)

• Aluminum hexagonal cell structure

• Maintains structural integrity

Airport Case Study:
Dubai Terminal 3 saved 3.2 tons total door weight by switching to honeycomb – reducing structural support costs by 18%

2. Fire Safety: Middle East’s Non-Negotiable Requirement

Our proprietary 3-layer protection system:

1. Aluminum Honeycomb Core:

• Melts at 660°C (vs steel’s 1,500°C) but…

2. Ceramic Fire Coating:

• Expands when heated, creating insulating char

3. Intumescent Seals:

• Swell to block smoke at 200°C

Test Results:

• 90-minute fire rating (BS 476-22 certified)

• 50% faster installation due to weight savings

3. Why Middle Eastern Airports Demand This Balance

✔ Climate Factors:

• Extreme heat warps traditional materials

• Sandstorms require tight seals

✔ Operational Needs:

• Frequent door cycling (50+ openings/hour)

• High passenger flow demands durability

4. Hidden Benefits Beyond Weight Savings

✔ Energy Efficiency:

• Thermal break technology reduces AC loss

• U-value improvement up to 35%

✔ Maintenance Advantages:

• No warping in humidity (common with solid core)

• Scratch-resistant powder coatings

5. Cost Analysis: Long-Term Value Wins

ROI Calculation:
Honeycomb doors pay back the premium in 4-6 years through:

• Reduced HVAC costs

• Lower manpower for operation

• Fewer replacements

Special Report: Our Doha Airport Project

For Hamad International’s expansion, we developed:

• Custom Hybrid Solution:

  • 30mm aluminum honeycomb core

  • 2mm fire-resistant ceramic coating

  • Anti-microbial handle system

Performance Metrics:

• Withstood 2-hour fire test at 950°C

• 22kg weight (vs competitor’s 38kg)

• 1.2 million cycle durability rating

Future Trends in Airport Doors

✔ Smart Integration:

• Weight sensors for maintenance alerts

• Automatic fire seal activation

✔ Advanced Materials:

• Graphene-enhanced cores (testing shows 40% strength increase)

• Self-healing surface coatings

Choosing the Right Solution

For your project consider:
✅ Passenger traffic volume
✅ Local fire regulations
✅ Climate conditions
✅ Long-term operational costs

The Lightweight Revolution

The lightweight honeycomb door isn’t just an alternative – it’s becoming the new standard where safety, efficiency and durability intersect. As airport designs evolve, these advanced materials prove that sometimes, lighter is actually stronger.

P.S. Download our free “Airport Door Specification Checklist” with 23 technical criteria for your next project!