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dnata Catering & Retail Case Study

Project Overview

dnata Catering & Retail undertook an AUS$50 million expansion of its Melbourne Airport facility, adding 5,700m² to the site and lifting its total footprint to over 16,000m². Once complete, it will be the largest airline catering centre in Victoria, with the capacity to produce 25 million meals a year
for dnata’s 20+ airline customers.

A project of this scale, in an active food production and airport-adjacent environment, demands door solutions that can meet strict fire, hygiene, and durability requirements without slowing down the build. Larnec was engaged to supply solid core steel-clad personal access doors, 120-minute fire-rated doors, and a full suite of commercial-grade hardware.

Solid Core Steel-Clad Personal Access Doors

Larnec supplied solid core, steel-clad pre-hung personal access doorsets throughout the facility. Pre-hung construction meant doors arrived frame-ready for installation, cutting time on site and keeping the build on schedule. The steel-clad, solid core build gives the doors the strength and impact resistance needed for a high-traffic commercial facility, while standing up to the demands of a 24/7 production environment.

A number of openings on this project called for custom sizes outside standard dimensions. Larnec manufactured doorsets to these custom specifications, giving the builder the flexibility to fit the door solution to the opening rather than redesigning the opening around a standard door.

Fire-Rated Personal Access Doors

Given the scale and use of the facility, a number of doorsets were supplied with a 120-minute fire rating. These doors meet the compliance requirements expected on a major commercial build of this type, giving the builder and client confidence that fire compartmentation is properly addressed without compromising
on the durability or finish of the doorset.

Hardware

To match the demands of a large-scale, high-traffic commercial facility, selected Larnec doorsets were fitted with a full range of upgraded hardware:

Panic bars — for safe, code-compliant emergency egress across the facility’s high-occupancy areas.
Door closers — specified to extend the working life of the doorset. In a high-traffic facility, self-closing hardware reduces wear on hinges and frames, prevents doors from being left open(important for fire compartmentation and hygiene in a food production environment), and cuts down on damage from slamming or forced closing.
Spring and chain door retainers — allowing doors to be safely held open during deliveries or peak movement periods, without compromising the door’s ability to self-close when needed.
Upgraded locksets — for the added security and access control a facility of this size requires.
Perimeter and bottom door seals — supporting hygiene and pest control in a food production setting, as well as contributing to climate control across temperature-sensitive areas.

Glass Viewing Panels

Selected doors were fitted with glass viewing panels, improving sightlines and safety in high-traffic areas while maintaining the fire and security performance of the doorset.

Complete Door Solutions, Delivered at Scale

Projects like the dnata Melbourne Airport expansion show what Larnec can deliver for Australia’s biggest builders: a complete door solution, from solid core and fire-rated doorsets through to the hardware and glazing that finish the job, including custom sizing where standard dimensions won’t do. Supplied in full and on time, to keep major commercial builds moving.

Ready to plan your next development?

Contact Larnec today to talk through expert door solutions for your commercial, industrial, or modular building project.