Heathrow Airport Fuelling Installation

REDS has recently successfully completed a specialist fuels infrastructure project for British Airways PLC (BA) at their Fleet Support Unit (FSU) hangar, located within their operations base area at Heathrow Airport.

Works comprised of three main activities:

• Provision of a replacement fuelling station to serve BA Engineering vehicles and equipment. This comprised constructing a new, above-ground containerised fuelling station on an airside apron to the immediate north east of the FSU hangar.
• Decommissioning of the existing fuel storage and delivery system located at the front of the FSU north doors. Works included the removal of the existing diesel fuel tank fill cabinet, fill point and dispensing pump and then in-filling the existing below-ground fuel tank.
• Construction of a new below-ground installation comprising specialist equipment designed to provide power to aircraft (specifically the Airbus A350) being worked on inside the FSU hangar. This was referred to as the ‘nose pit’ and required construction of a below-ground chamber for the equipment, and new ducts for provision of new 400Hz cable connections.

Construction of a New Fuelling Installation

The project involved establishing the main works area by creating a new gated access route, closing an aircraft stand, and isolating the construction site with airside-approved barriers. A site survey identified all below-ground services, and the final layout for the new fuel tank, oil/water interceptor, and drainage trenches was set out considering existing utilities.

Specialist concrete cutting was completed, revealing pavement concrete up to 800mm thick and mass concrete obstructions. Excavation of over 55m of trench connected the new installation to the airport’s drainage system, with the construction of four access chambers. The drainage work was prioritised to hand back the aircraft stand to British Airways (BA) as soon as possible.

The installation of the oil/water interceptor required sheet-piled temporary works to manage shallow groundwater and safely install the interceptor and penstock control valves. Foundations for the tank and its dedicated drainage system were constructed, and new duct work for the tank’s power and control systems was carefully planned around existing utilities.

Electrical installations were carried out by REDS specialist electricians, and once the fuel tank was installed, the surrounding pavement was reinstated and road markings applied. The tank was commissioned, tested, and handed over to BA for use.

Decommissioning of the Old Fuel Island

Following the commissioning of the new fuelling installation, the old fuel islands and underground tank near the FSU hangar’s northern doors were decommissioned. The fuel dispenser was removed, and the fuel island and drainage gullies were broken out before reinstating the concrete pavement.

REDS Environmental Consultants conducted soil verification sampling to confirm no residual contamination. The former fuel tank and lines were drained, cleaned, and decommissioned in-situ by filling the tank with foam concrete.

Nose Pit Installation

Though not the largest part of the project, the works inside the operational FSU hangar required meticulous planning alongside BA Engineering to coordinate the excavation sequence. A main nose pit excavation (~2.5m x ~5m, 2.5m deep) was carried out about 25m inside the southern hangar door, with new ducts installed to connect electrical cables from two existing chambers.

The 800mm thick concrete floor required specialist airside cutting techniques for the excavation. Contingency measures, including aircraft-rated steel plates provided by BA, were used to cover open excavations at the end of each shift.

The airside equipment housing was installed, ducts constructed, and electricity cables were drawn to the new nose pit. The hangar floor was reinstated, with final works involving the provision of new electrical cables and a compressed air supply to an existing chamber.

Results

The dedication and detailed project management, alongside the collaborative efforts of our diverse teams, were instrumental in the successful completion of this major aerospace project.

Our proven track record within the aerospace environment, combined with an in-depth understanding of project requirements, exceptional problem-solving skills, and remarkable adaptability, ensured this complex job was delivered to the highest quality standard while prioritising safety at all times.