Case Studies

Rolls Royce – HAG supplies doors for the world’s largest exhaust pipe


Rolls Royce are a British multinational aerospace company, whose business was established in 1904. They design, manufacture & distribute power systems for aviation & other industries and they are the world’s second largest maker of aircraft engines.

2021 sees Rolls Royce unveil Testbed 80, the world’s largest & smartest indoor aerospace testbed, as part of a £90million investment. It has been a hard year for the aerospace industry, with production slowing, and cuts in jobs, however this ground breaking facility shows Rolls Royce’s confidence in the future of aerospace for decades to come.


HAG Ltd. have proudly worked alongside Buckingham Group to assist in this ground breaking facility that will not only test propulsion systems of the future, but also secure jobs in Derby, UK for many years to come.

We were tasked with designing, manufacturing & installing a highly insulated industrial door, over the world’s largest exhaust pipe.

The Project

HAG Ltd. were tasked with designing & manufacturing a roller shutter for this distinctive & state of the art facility, to enable Rolls Royce to test the largest, smartest and most powerful engines in the world by MDS Aero Support Corporation of Ottawa, Canada.

Our product enabled Rolls Royce to support all three pillars of their sustainability strategy. Firstly, continuing to improve the efficiency of the gas turbine. The facility has been designed to test a range of today’s engines, including the Trent XWB and the Trent 1000, but will also have the capability to test the UltraFan® demonstrator, the blueprint for their next generation of engines. UltraFan will be 25% more efficient than the first Trent engine, and we will begin ground testing the demonstrator at the testbed in 2022.

HAG Ltd.  designed, manufactured and installed 2 Armourguard F1 insulated roller shutters that were 7.5m by 15m. The F1 model is a high quality insulated security shutters delivering the highest level of security and offering thermal protection. A composite of foam filled sections is encased in a flat double skinned interlocking galvanised steel lath.

“The biggest challenge of this project was to create an anti-fall back up system, as the doors were too big for safety breaks, to prevent the door from free falling in the event of motor failure. We decided that the safest option was to introduce a dual motor system” – Jason Jones, HAG Ltd. Technical Manager

The door solution has brought the following benefits to the customer:

Warren East, Chief Executive, Rolls-Royce, said: “Testbed 80 is the largest facility of its type in the world. However, it is not only big, it is also smart and features the most advanced testing technology we have ever used. As the new global hub of our testing capability, it will support the next stage of our UltraFan programme as we begin ground testing the first demonstrator in 2022. This incredible piece of infrastructure is a very visible sign of our commitment to this site and secures the future of Derby as the home of large engine development, continuing a history that began in the late 1960s with the RB211.”

HAG Ltd. are proud to be part of this monumental development in the aviation industry.

Talk to the
door specialists

Contact Us

HAG offers a wide range of products and services, if you would like further information call 0800 072 3444 now to speak to a member of our team.

Case Studies