Gloucester

Copperchase and Gloucestershire Airport share a commercial partnership pning more than 25 years. This relationship dates back to the early 1990s when the airport became one of the first adopters of the Copperchase DOS-based AFTN Terminal, AFTERM. Following the recent implementation of an Airfield Lighting Control System at the site , airport management initiated a comprehensive tower upgrade.

The primary objective was to modernise the airfield’s critical technical infrastructure, future-proof operational capabilities, ensure regulatory compliance, and deploy state-of-the-art systems designed to meet future aviation demands. Copperchase was contracted to deliver a complete turnkey solution providing total project management, supply, and installation for the core communication, meteorological, and flight data processing elements.

Scope of Supply & Systems Delivered

The project brought together real-time data integration, advanced voice broadcast/circuit switching, and ergonomic modernisation under a unified project plan.

1. Voice Communications & Control System (VCCS)

To replace the legacy Drake system , Copperchase supplied and installed a highly reliable, touchscreen-based Voice Communications Control System based on the MEP TCS990 architecture. The configuration includes:

• Operator Working Positions (OWP): Four 12-inch TCP995 operator panels split into three operational slots in the Visual Control Room (VCR) and one technical station in the equipment room.
• Channels & Interfacing: 8 Transmitter and 9 Receiver channels configured via 4-wire E&M, fully upgradeable to ED137 VoIP standards, alongside 8 PABX telephone lines.
• Accessories: 20 Sennheiser HME43 headsets equipped with coiled cabling and in-line Press-To-Talk (PTT) switches , paired with ACU995 headset connection panels providing dedicated ATCO1, ATCO2, and Mentor positions with PTT override capabilities.

2. Voice Recording System (VRS)

A fully redundant, dual Copperchase AIR voice and data recorder system was integrated directly into the VCCS equipment rack. The system uses an intuitive web-based GUI interface allowing users to access, review, view charts, or download audio directly from a dedicated replay client station. The recorder continuously logs:

• 24 analogue channels.
• 7 VoIP channels.
• Combined electronic data streams, including synchronised audio, data sessions, and network interactions.

3. Meteorological Processing & Sensors (METSYS)

The legacy Muir Matherson Aviation (MMA) setup was fully replaced by an automated Copperchase METSYS linked to high-performance field instruments positioned at a newly established Met Garden near the NDB shelter. Communication between the field sensors and the central servers leverages modulated RS485 serial data converted over the airport’s existing fibre optic network via Fibre Field Communication Boxes. Hardware components conform to ICAO and WMO regulations and include:

• Vaisala AWS310 Automated Weather Station: Compact logger housed inside a stainless-steel enclosure.
• WMT703 WINDCAP Ultrasonic Anemometer: A maintenance-free sensor with no moving parts for wind speed and direction accuracy.
• HMP155 Temperature & Humidity Probe: Fitted within a DTR13 radiation shield to filter solar reflection.
• PTB330 Digital Barometer: Features three independent silicon capacitive absolute transducers to enforce strict system redundancy.
• CL31 Cloud Base Recorder (Ceilometer): Uses pulsed diode LIDAR technology to scan up to three simultaneous cloud layers to a range of 7.6 km.
• DKP210 10-Metre Tiltable Mast: Robust winched mast system engineered to safely withstand extreme wind conditions.

4. Automatic Terminal Information Service (ATIS)

Integrated seamlessly with the METSYS and Weather Editor applications , the ATISPREP software automatically tracks sensor feeds and compiles current runway surface conditions into broadcasts. It features automatic phraseology adjustments mapped to the latest Global Reporting Format (GRF) directives , generating simultaneous voice transmissions over both VHF and PSTN telephone lines.

5. Flight Data Management System (FDMS)

Migrating from text-file-based processing (AFGATE) to a modern Microsoft SQL Database repository , the new FDMS client operates across the tower assistant and reception desks. The system automatically translates incoming flight schedules, departure slot allocations, and routing files into printable layouts handled via the existing IER Flight Strip Printers. It also contains a cloud-based B2B internet protocol interface directly linked to the airport’s new Nevalee Red Atlas Airport Management System (AMS) , tracking active movements to optimise automatically generated landing fees and invoicing data.

6. ATC Information Display System (ATC-IDS)

Operating as a securely firewalled and whitelisted visual portal , the ATC-IDS display system consolidates approach charts, PDF manuals, shift documents, and real-time internet feeds (e.g., Met Office Aviation Briefing Service) into multi-monitor arrays at the ATCO and reception positions.

Project Assurance & Comprehensive Management

A significant asset of the project configuration was Copperchase’s ability to coordinate externally sourced services alongside their standard technical delivery. Gloucestershire Airport directly contracted a series of core components, including specialised ergonomic ATC console furniture, structural data/electrical cabling installations, and the localised operational Safety Case processing. Copperchase acted as the lead contractor, mapping these parallel dependencies directly into an overarching project plan led by a dedicated Project Manager.

Project Assurance & Comprehensive Management

A significant asset of the project configuration was Copperchase’s ability to coordinate externally sourced services alongside their standard technical delivery. Gloucestershire Airport directly contracted a series of core components, including specialised ergonomic ATC console furniture, structural data/electrical cabling installations, and the localised operational Safety Case processing. Copperchase acted as the lead contractor, mapping these parallel dependencies directly into an overarching project plan led by a dedicated Project Manager.

The project execution adhered to rigorous standard quality baselines:

1. System Design Documentation: Meticulous translation of hardware, software, and physical layout designs for customer approval prior to manufacturing.
2. Factory Acceptance Testing (FAT): Staged component builds, technical integration tests, and configuration walk-throughs completed at the Copperchase Cramlington manufacturing facility.
3. Overnight Transition & Commissioning: To avoid operational impact on one of the UK’s busiest regional airfields, final hardware changeover was successfully compressed into a single overnight shutdown window between 20:00 and 08:00, utilising structured roll-back contingencies and keeping the UK CAA fully updated throughout.
4. Site Acceptance Testing (SAT) & Training: Field calibration, on-site infrastructure validations, and thorough operational/technical training packages delivered across engineering and tower teams.

Conclusion

By leveraging over three decades of engineering experience , an ISO9001 certified build standard , and strong strategic alliances , Copperchase delivered a modern, multi-disciplinary tower environment for Gloucestershire Airport. The resulting solution successfully integrated communication channels, safety logging, real-time weather sensors, and accounting intelligence into a robust system architecture—guaranteeing operational accuracy, safety compliance, and high system availability for years to come.