Acoustic laboratory noise control within a working brewery facility

Flexshield solution:

The project required two distinct acoustic door openings:

• A personnel access point for daily use, incorporating emergency escape capability while maintaining acoustic performance, and
• A wider opening that needed to achieve higher levels of noise reduction across a larger span, to accommodate operational requirements within the laboratory space.

Both openings were positioned within an existing, structurally complete fitout. This meant each door assembly needed to be engineered to suit finished square-set openings without structural modification, placing demands on dimensional accuracy and installation methodology.

Flexshield designed, manufactured and installed two custom acoustic door systems. Both products were manufactured in Australia, enabling the design to be developed to exact project specifications and adjusted to suit site conditions as the program evolved.

The acoustic doors were specified as the final stage of the broader laboratory fitout, requiring precise timing within the overall construction program.

Sonic Access acoustic personnel door

Manufactured to suit the primary laboratory entry point, a Sonic Access acoustic personnel door was engineered to precisely fit the existing square-set framing.

The door achieves Rw 36 NATA-tested acoustic performance, providing independently verified noise reduction between the production floor and the laboratory interior. Acoustic seals incorporated throughout the door design and drop seals to the floor ensure continuous acoustic integrity at the threshold.

The door was configured for emergency escape, with a door closer and stainless steel kick plates on both faces. An integrated viewing panel maintains sightlines without affecting acoustic performance.

A steel retrofit pressed frame was manufactured to insert directly into the existing square-set opening, and powder coated to match the finish. The pre-hung design allowed fast, accurate installation on site, and Australian manufacture ensured the door was produced to the exact required dimensions.

Custom electric sliding acoustic door

The wider opening required a higher-performance acoustic treatment across a larger span. Flexshield designed and manufactured a custom electric sliding acoustic door to suit. Shop drawings were provided for client sign-off before manufacture commenced.

Mid-project, the required opening width was revised to reflect updated site requirements. Through close coordination with Box & Co, Flexshield utilised its Australian manufacturing capability to absorb this change without significant impact on the program or the final outcome.

The electric sliding acoustic door achieves Rw 47 independently verified performance. Central to this acoustic performance is the hermetic track system with floor guides. As the panel closes, the system moves it both inward and downward, compressing the acoustic seals and maintaining the Rw 47 rating. This engineering approach reflects Flexshield’s focus on delivering practical acoustic outcomes through purpose-designed, Australian-manufactured products.

The door is fully motorised with push-button controls on both sides, battery backup, and an anti-crush sensor for safe operation. Stainless steel kick plates were installed on both faces, and an acoustic-rated viewing panel matches the personnel door’s configuration.

Installation

Flexshield’s trained and licensed team carried out installation as the final stage of the laboratory fitout. As the installation window approached, a complimentary pre-installation site inspection confirmed site readiness and addressed any interface matters before work began.

Close coordination with Box & Co and the broader project team ensured the installation was fully aligned with the approved program.