Baggage Chute Modification & Relining – Manchester Airport
Design, Engineering & Composite Upgrades for a Major UK Contractor
Overview
A major UK contractor approached us to resolve ongoing performance issues with several baggage-handling chutes at Manchester Airport.
The existing sheetmetal chutes were not performing as required: bags and suitcases were jamming, slowing down or piling up due to the steel's inability to form the precise curved profiles the system needed for smooth flow.
We were tasked with:
- Improving the chute geometry
- Delivering a hardwearing, long-life solution
- Ensuring a full Class 1 fire rating
- Bonding the new GRP lining to the existing steel structure
- Completing each chute with rapid turnaround during short operational windows
- Recording and signing off on every stage for airport compliance
The result was a fully upgraded set of chutes that remain in successful service today, providing reliable baggage flow from check-in to the aircraft.
The Challenge
The project presented several significant constraints:
Existing Steel Chutes Could Not Achieve Smooth Flow
The original sheetmetal construction could not form the tight, uniform curves required for consistent luggage movement.
This caused:
- Bags to jam or stall
- Buildups in corners
- Delays in the baggage system
- Increased manual intervention
Extremely Limited Time Windows
The chutes could only be removed from service for short periods.
This meant:
- Collection in the early hours of the morning
- Complete stripdown, resurfacing, laminating, curing and finishing
- Return and reinstallation on the same night
Every chute had to be turned around within hours, not days.
Requirement for HardWearing, LongLife Surfaces
Airport baggage handling involves:
- Abrasion
- Impact
- Drag
- Continuous mechanical contact
The final GRP surface had to withstand years of heavy use without wearing through.
Mandatory Class 1 Fire Rating
All materials used in airports must meet strict fire safety standards.
Both the laminate and topcoat system had to achieve Class 1 fire performance.
Full Traceability & Quality Recording
Every process step needed to be logged:
- Laminate thickness
- Material batch numbers
- Cure temperatures
- Postbake temperatures
- Surface preparation records
- Sign-off sheets for every chute
This level of documentation was essential for the approval of airport operations.
Our Solution
Precision Reshaping & Profile Correction
Once each chute arrived at our facility, we:
- Removed all existing paint
- Ground back the steel to a clean bonding surface
- Sculpted the required curves using specialised composite infills
- Rebuilt the geometry to create the correct continuous flow profile
High-Strength GRP Relining System
We laminated each chute with a heavy-duty GRP layup, engineered for:
- Impact resistance
- Abrasion resistance
- Long-term wear
- Structural bonding to steel
- Class 1 fire rating
Ultra-Smooth Topcoat System with Special Additives
The final surface finish included:
- A smooth internal surface
- A gel topcoat engineered for low friction
- High-wear additives incorporated into the coating
- A durable finish able to withstand years of baggage movement
This dramatically reduced friction and eliminated bag hangups and jams.
Controlled Curing & Post-Bake Treatment
To meet performance and fire-rating standards, each chute was:
- Initially cured
- Post-baked in our controlled oven
- Temperature logged throughout
- Verified to meet the correct cure parameters
This ensured stability, hardness and long-term durability.
Rapid Collection, Turnaround & Return
We operated on an overnight turnaround cycle:
- Collected chutes during early-morning downtime
- Ground, rebuilt, relined and finished during the day
- Oven-cured components on-site
- Returned and reinstalled before the next operational period
Despite the short notice and high urgency, we never missed a single deadline.
The Outcome
- All chutes were completed on time, even during short-notice quests
- Flow problems completely resolved — no more bag pileups
- All chutes are fully Class 1 fire-rated
- Hardwearing surfaces that continue to operate for years later
- Full traceability and documentation provided for every unit
- A very satisfied contractor and an ongoing working relationship
These upgraded chutes are still actively transporting luggage to aircraft today, providing the reliability Manchester Airport required.
Need a Similar Industrial Composite Solution?
From complex relining work to precision GRP rebuilds, moulds and structural upgrades, we deliver fastturnaround, high-performance solutions for challenging environments.
Contact us below to discuss your requirements.
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