German airport taps Gates for hydraulic hose overhaul

Luxembourg – A major German airport is replacing failed hydraulic hoses in its passenger airbridges with Gates technology after a series of breakdowns disrupted operations.

The unnamed airport has seen unexpected failures in its original hose assemblies, rendering airbridges inoperable, Gates announced 7 April.

The airport, which handles 60 million passengers and over 430,000 aircraft movements annually, is now using Gates MegaSys hoses with a MegaTuff cover to replace failed competitor hoses.

According to Hydraulic specialist Form-Plast GmbH, which is carrying out the replacements, the existing hoses primarily failed due to premature wear, pinholes, and cracking.

The original hoses supplied with the airbridges were “not durable enough” for the operating environment, particularly due to prolonged oil exposure, explained Form-Plast managing director Andreas Held.

Each overhaul requires six to 15 hose assemblies, along with specific couplings and routing adjustments to reduce mechanical stress. So far this year, Form-Plast has replaced hydraulic systems in 24 airbridges.

“When a hydraulic failure occurs on an airbridge, the impact on operations is significant, leading to passenger delays and potential damage to aircraft,” Held said.

“An airbridge unable to maintain the correct height during boarding or disembarking risks damaging the fuselage, particularly around the aircraft door.”

The new Gates hoses are designed to withstand abrasion, oil exposure, and UV degradation while maintaining flexibility for easier installation.

The overhaul is expected to ensure the airbridges remain operational for their intended six-year service window.