Manchester Airport Ceiling Foils Delivered in 3 Weeks

The programme for the new gates at Manchester Airport required ceiling foils far sooner than the traditional supply route could deliver them.

A standard lead time of around 14 weeks did not work for the project. Innovate at SA supported Mace with a practical offsite solution and delivered the required ceiling foils in 3 weeks.

Our team modelled the detail, produced a mock-up, cut and dry test-fitted the components, labelled every part and organised delivery. This gave the site team a faster and more controlled route to installation in a live airport environment.

FAST FACTS LINE

Fast-Track • Ceiling Foils • Live Airport • Offsite Preparation • 3-Week Delivery

From Model and Mock-Up to Site-Ready Ceiling Foils

The Ceiling Foil Lead-Time Challenge

Turning a 14-Week Lead Time into a 3-Week Delivery

Mace needed a faster way to deliver the ceiling foils for the new gates at Manchester Airport.

The traditional route suggested a lead time of around 14 weeks, which did not work with the project programme.

Because the work formed part of a live airport environment, the components also needed to arrive checked, clearly labelled and organised for installation. Sending unresolved details to site would have added cutting, dust, time and uncertainty.

In short, the challenge was to turn the ceiling foil design into accurate, test-fitted and site-ready components within a 3-week delivery programme.

Our Solution

Modelling, Mock-Up and Offsite Preparation

Innovate at SA supported Mace by turning the ceiling foil details into a controlled offsite manufacturing process.

Our team developed the model and produced a physical mock-up before moving into full production. This allowed the detail and manufacturing approach to be checked early.

Once agreed, we cut the individual components, dry test-fitted the parts in our workshop and labelled them for the installation sequence.

The completed ceiling foils were then organised and shipped to Manchester Airport. The site team received checked, clearly identified components instead of having to resolve the detail in the live working area.

By completing the modelling, checking and preparation before dispatch, we created a faster and more controlled route to installation.

“Thank you Tony, great effort by your team for the model, mock up and delivery”

Michael Weed, Associate Director, Mace Group

What We Delivered:

Ceiling Foil Modelling

Physical Mock-Up

Precision-Cut Ceiling Foil Components

Dry Test-Fitting Before Dispatch

Clearly Labelled Parts for Installation

Delivery Within 3 Weeks

The Outcome:

14 Weeks Compressed to 3 Weeks

The traditional route suggested a lead time of around 14 weeks. Innovate at SA delivered the ceiling foils in 3 weeks.

Our offsite process gave Mace a faster and more controlled route from the original design to site-ready components.

The site team received accurately cut, test-fitted and labelled parts that were organised for installation in the live airport environment.

Why Offsite Ceiling Foil Preparation Makes Sense

A Shorter Programme

We brought modelling, mock-up production and manufacturing together within one controlled offsite process. This helped compress the expected lead time from 14 weeks to 3 weeks.

Less Work in a Live Environment

Preparing the components in our workshop reduced the amount of work, dust and disruption transferred to the live airport environment.

More Control Before Delivery

We checked the ceiling foil components, labelled the individual parts and organised them before dispatch. This gave the site team a clearer route to installation.

Less Site Cutting

The components arrived already cut and prepared, reducing the amount of cutting and forming required on site.

Consistent Components

CNC cutting followed the agreed model, helping to maintain accuracy and consistency across the individual components.

Cleaner Installation

Completing the cutting and dry test-fitting in our workshop kept more of the dust, waste and preparation work away from the installation area.

FAQs

What did Innovate at SA deliver for Manchester Airport?

We supported Mace with the modelling, mock-up, cutting, dry test-fitting, labelling and delivery of ceiling foil components for the new gates at Manchester Airport.

How quickly were the ceiling foils delivered?

The traditional route suggested a lead time of around 14 weeks. Innovate at SA completed the offsite process and delivered the ceiling foils in 3 weeks.

Why were the ceiling foils prepared offsite?

The project had a tight programme and formed part of a live airport environment. Offsite preparation provided greater control while reducing the amount of cutting, dust and preparation work required on site.

How were the ceiling foil components checked before delivery?

Our team developed the model and produced a physical mock-up before manufacturing the components. We also dry test-fitted the cut parts in our workshop before dispatch.

How were the components prepared for installation?

We labelled and organised the individual components before shipping them to Manchester Airport. This gave the site team a clear sequence to follow during installation.

Can Innovate at SA support other fast-track ceiling projects?

Yes. Send us the drawings, required programme and available project information. Our team can review the detail and identify which elements could be modelled, cut, test-fitted and prepared offsite.