AeroDoor Completes 7-Bay Hangar Door System for The Marshall Group’s U.S. Facility

Design & Fabrication, Unloading, Door Installation, Electrical Installation, Owner Training

AeroDoor International has successfully completed the engineering, fabrication, and installation of two large-scale horizontal rolling steel door systems for The Marshall Group, a global leader in aerospace and defense. The completed systems span a combined 1,042 feet of aircraft hangar frontage and support the company’s expanding U.S. operations, including a dedicated paint hangar bay.

The project consisted of a 3-bay door system measuring 421 feet wide by 42 feet tall, and a 4-bay system measuring 621 feet wide by 42 feet tall. Each bay is independently operated and was custom designed to match site-specific requirements. The 4-bay system includes the facility’s paint hangar at one end, with extra weather seals installed to meet that environment’s tighter containment needs.

“This is one of the most extensive hangar door packages we’ve delivered to date,” said Paul Blake, Project Manager at AeroDoor. “It involved not just size and complexity, but also precision—integrating features like ADA-compliant man door openings, exhaust hatches, and electrical scope, all while meeting tight tolerances and performance standards.”

Installation was executed in four planned mobilizations: bottom rail and leveling angle installation, top track and door hanging, motor and electrical setup, and final owner training. All rental equipment was provided by AeroDoor, and installation was closely coordinated with on-site teams to ensure safe, efficient delivery.

“The result is a set of robust, operator-friendly doors that match the scale and sophistication of The Marshall Group’s aerospace operations,” added Paul Blake. “It’s a project we’re proud of—both for its technical quality and the relationship built with a first-class client.”

Key system features include

  • 4-Bay System: 621′ x 42′, four panels operating on four rails

  • 3-Bay System: 421′ x 42′, three panels operating on three rails

  • Independently operated bays with recessed motor and control panels

  • Telescoping pogo door rollers providing +6″ to 9″ of vertical deflection

  • ADA-compliant man door openings and rough openings for windows

  • Soffit closure plates for a clean overhead transition

  • Exhaust hatches integrated in select bays

  • Electrical wiring, conduit, and operator stations fully furnished and installed by AeroDoor

  • Weatherseal system enhanced specifically in the paint hangar bay

  • Designed to 115 MPH Ultimate wind load, Exposure C

  • PE-signed engineering calculations and L/120 horizontal deflection criteria

  • 25-year structural and 1-year electrical/mechanical warranties

Marshall Group Hangar Door Project Overview