Hydraulic hose upgrade boosts airbridge reliability at major German airport

26 June, 2025

The airport is now using Gates MegaSys hoses with a MegaTuff cover to replace failed competitor hoses, which have been prematurely breaking down.

Handling 60 million passengers and over 430,000 aircraft movements annually across three terminals, the airport can’t
afford the operational disruption caused by these failures.

Hydraulic experts and Gates partner, Form-Plast GmbH, is conducting the replacement work, which includes removing the defective hose assemblies from the airbridge hydraulic system and performing a complete overhaul.

Form-Plast’s managing director, Andreas Held, noted the original hoses supplied with the airbridges were not durable enough to withstand typical operating conditions, which often include prolonged immersion in oil. Inspection revealed pinholes, cracks, and significant wear, rendering the airbridges out of service and disrupting airport operations.

Each overhaul requires between six and 15 hose assemblies, specific couplings, and careful routing to reduce stress under operating conditions.

This year alone, Form-Plast has replaced 24 airbridges. Reflecting on the project, Andreas Held commented: “The airport operators were concerned about the unexpected, premature failure of the original hoses before their six-year replacement schedule.

“However, we have successfully allayed those fears with Gates hoses. Records from a previous Gates hose installation in 2018 proved that Gates hoses could perform reliably over time in this environment.”

Held added: “When a hydraulic failure occurs on an airbridge, the impact on operations is significant, leading to passenger delays and, more critically, potential damage to the aircraft. An airbridge unable to maintain the correct height during boarding or disembarking
risks damaging the fuselage, particularly around the aircraft door.”

Gates says its MegaTuff hoses are exceptionally resistant to abrasion, oil, ozone, and UV exposure, due to the material science behind the specifically designed cover compound as well as the process engineering to ensure the cover remains intact and does not peel under demanding conditions. Importantly, they also maintain their flexibility and minimum bend radius, which simplifies installation and enhances durability.

Seamless port-to-port solution

The installations, according to Gates, have demonstrated impressive performance with no leaks or defects, a result of Gates’ extensive research and development to create a seamless port-to-port solution. The hose and coupling combinations are designed to work seamlessly, offering trouble-free service throughout its working life, as Form-Plast’s experience confirms.

Held concluded: “By using Gates MegaSys MegaTuff hose assemblies, we have resolved these unexpected issues, eliminating airbridge failures and ensuring that they remain operational for the six-year window, keeping operations running and reducing the airport operator’s maintenance costs in the long term.”

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