Designed, built and fitted out in-house.

Manufacturer-direct pricing. No subcontracted assembly, no white-labelled output, no exposure to a third-party schedule. Mechanical, structural, fit-out and QA all sit inside the group across the UK and Poland.

Engineering & Manufacturing

Group HQ: Dudley, UK
EU HQ & factory: Słupy, PL · 11,000 m²
Proving ground: Builth Wells, Wales
Partners: Japan (Tokyo) · USA (Sprung)
Procurement routes: SAM · DLA · Direct

Engineering that stays connected to the build.

Engineering & build, connected

BANAIR Group engineering is not separated from manufacturing. Design, configuration, technical visualization, fabrication review and installation planning are connected early, so systems are built around real operational, transport and site constraints.

What this gives the buyer

One accountable engineering and manufacturing team
CAD-driven design, technical renders and configuration support
Review against transport, installation and field-use constraints
Manufacturer-direct configuration changes where required
Systems designed to be buildable, supportable and procurement-ready

Two fitters bolting up a long lattice beam supported on timber trestles in the Słupy shop, with completed lattice sections stacked in the foreground and racking behind

Engineered to defined standards.

Standards

BANAIR Group systems are engineered around the duty cycle, load case, environment and deployment method they must support.

Steel: Structural steel to S355 / ASTM A572 Grade 50 equivalent
Finish: Hot-dip galvanized to EN ISO 1461 / ASTM A123
Racking: Storage racking compatible with NFPA 13 and UFC 3-600-01
Envelopes: Heavy-duty operating envelopes across ramp, rail, shelter, storage and cargo systems

The shop floor, photographed.

On the line

Profiling, fabrication, assembly and inspection — the four stages every BANAIR Group system passes through in-house.

A galvanised section running out of the roll-forming line at Słupy, the operator working at the machine head and further profiling machines ranged down the bay — On the line
Profiling on the Słupy line

UK and Poland in-house. Japan and US partner network.

Manufacturing

Dudley (UK) runs precision fabrication, CNC machining, R&D and destructive testing. Słupy (PL, 11,000 m²) runs full fabrication, CNC sheet metal and integrated coating lines. Builth Wells (Wales) handles large-scale prototyping; US partners such as Sprung extend capability for US defense procurement.

In-house capability includes

Precision steel and structural fabrication
CNC machining, turning, laser & plasma profiling, punching and folding
Powder-coating, wet spray, shot blasting and custom coatings
Destructive testing, prototyping and an on-site demonstration area
Manufacturer-direct pricing on BANAIR Group equipment

A machinist working inside a CNC machining centre in the BANAIR UK plant, flanked by two further machining centres, with a long aluminium section set up on the machine bed and a stack of curved aluminium profiles on a timber pallet in the foreground

Galvanised MUDR platform sections stacked and strapped into a single transport package, banded onto timber bearers ready to ship

From requirement to deliverable system.

Process

BANAIR Group turns operational requirements into systems that can be manufactured, shipped, installed and supported.

See the six steps

Requirement and operational scoping.
Concept and configuration development.
Engineering and technical visualization.
Fabrication, assembly and in-process QA.
Shipping, installation and handover support.
Post-deployment service where agreed.

Proof in the product families.

Proof

Four families, four engineering problems — adjustable racking, rated ramp and rail structures, 463L-transportable cargo handling, shelters configured to site.

Storage

IARS™ rack heights can be adjusted by forklift on six-inch centres without bolts, supporting changing inventory and mission-equipment requirements.

Ramp and rail

MUDR™ and RM90 systems support heavy vehicle loading, washing, inspection and rail operations with defined load ratings and deployable transport logic.

Cargo handling

The Air Cargo Dock supports 463L and ISU90 cargo handling, with a six-bay system designed to dismantle onto a single 463L pallet.

Shelter and accommodation

DMTSS™, MPU and related shelter systems are configured around site conditions, climate requirements, transport method and operating use.

Welding, qualified and supervised.

Welding & process control

Welding is a controlled special process. Procedures are qualified by a notified body, welders certified, every project supervised by a coordinator — records held per weld.

Read the process detail

Procedures: WPS approved to EN ISO 15614-1 — processes 135 · 136 · 141 · 142 and laser (52).
Welders: Certified to EN ISO 9606-1.
Coordination: Welding supervised by a qualified coordinator to EN ISO 14731.
In-process control: Systematic checks at prefabrication, welding, surface treatment, assembly and packing — not a final add-on.
Traceability: Every weld, welder, material batch and inspection result documented across the product life cycle.

Technicians gauge-checking a machined spaceframe node on the workshop floor

Engineering and build records, on request.

Documentation you can request

Released to verified procurement contacts. Tell the team the product family and procurement route.

Engineering drawings & CAD: PDF · CAD pack on request
Welding records: WPS (EN ISO 15614-1) · welder qualification (EN ISO 9606-1)
Material certificates: EN 10204 — steel, consumables, coatings
Configuration matrices: Variants, options and deployment profiles
Capability & certification pack: IMS certificates, scope, standards mapping

Talk to engineering

Need engineering input before choosing a product family?

Tell BANAIR Group the requirement, environment, load case, site conditions and delivery context. The team will help translate it into a manufacturable and supportable configuration.