Case Study: Automated Gate System Overhaul and Modernisation
Project Overview
We were commissioned to undertake a comprehensive overhaul of an existing automated double swing gate installation. The gates were of substantial size and constructed from solid steel, placing significant demands on the automation system. The existing electro-mechanical operators were under-specified for the application, resulting in reliability concerns and increased mechanical stress on the gate structure.
Our objective was to modernise the installation, improve operational reliability, enhance safety compliance, and provide a long-term solution capable of handling the considerable weight of the gates.
Before:
The Challenge
The existing automation system had been installed on a pair of very large and heavy steel swing gates. Over time, it became evident that the electro-mechanical operating equipment was not adequately specified for the weight and operating demands of the gates.
Additional challenges included:
• Ageing and under-specified gate automation.
• Gate sag caused by wear and insufficient load-bearing support.
• A poorly managed cable infrastructure containing redundant and unsuitable internal-grade cabling.
• Outdated control equipment and housing.
• The need to improve safety systems to meet current compliance requirements.
• Drainage concerns around the underground drive units that could affect long-term reliability.
Given the size and weight of the gates, specialist lifting equipment was required to safely carry out the refurbishment works.
Engineering Solution
Heavy-Duty Hydraulic Automation Upgrade
Following a full site assessment, we specified and installed a robust 230V hydraulic automation system. Hydraulic operators are particularly suited to heavy-duty applications and provide significantly improved performance, durability and reliability when compared with the existing electro-mechanical equipment.
The new system was selected specifically to accommodate the weight and operating characteristics of the solid steel gates.
Structural Improvements
To address gate alignment and long-term structural stability:
• Existing gate hinges were removed and replaced.
• New pier spreader plates were fabricated and installed.
• Hinges were re-engineered to provide improved load distribution and weight-bearing capacity.
• Gates were carefully re-aligned to eliminate sagging and ensure smooth operation.
Due to the substantial weight of the gates, a HIAB crane was utilised on-site to safely lift, reposition and support the gate leaves during refurbishment works.
Electrical and Control System Renewal
The existing cabling infrastructure had evolved into a patchwork installation over many years, incorporating redundant wiring and unsuitable internal-grade cables exposed to external conditions.
To ensure long-term reliability:
• Redundant cabling was removed.
• New external-grade cabling was installed throughout.
• Conduit routes were rationalised and organised.
• Control electronics were completely replaced.
• A new control cabinet was installed and professionally sealed against environmental ingress.
The result was a significantly cleaner, more maintainable and more reliable installation.
Before Overhaul
After Overhaul
Safety and Compliance:
Safety formed a key part of the project design.
A comprehensive risk assessment was undertaken, with residual hazards mitigated through the installation of:
• Resistive safety edges.
• Infrared safety beam protection.
• Dual gate safety lanyard system.
• Modern control equipment incorporating current safety standards and monitoring functions.
This layered safety approach ensures safe operation for both vehicle and pedestrian users while supporting compliance with current automated gate safety requirements.
Drainage and Longevity Improvements:
To improve system resilience and reduce future maintenance requirements, drainage provisions were incorporated around the underground drive units.
These improvements help prevent water accumulation around critical mechanical components, supporting:
• Improved reliability.
• Reduced risk of corrosion.
• Extended equipment lifespan.
• Lower long-term maintenance costs.
Project outcome:
The completed installation transformed an aging and under-specified automation system into a robust, compliant and reliable solution capable of handling the demands of the heavy steel gates.
Key Benefits:
✔ Heavy-duty 230V hydraulic automation suitable for gate weight and usage.
✔ Improved gate alignment and reduced structural stress.
✔ Fully renewed control and electrical infrastructure.
✔ Enhanced safety and compliance measures.
✔ Improved drainage and long-term reliability.
✔ Professional cabinet installation and cable management.
✔ Increased operational lifespan and reduced maintenance requirements.
The Result
The client now benefits from a professionally engineered gate automation system that delivers reliable day-to-day operation, improved safety performance and a significantly extended service life, ensuring the installation remains fit for purpose for many years to come.