Heathrow Airport Control Tower

Scope

The works required areas of corrosion to be identified, prepared and repaired before the application of new protective coatings. All works had to be delivered within the operational environment of Heathrow Airport, without interfering with the continued operation of the Air Traffic Control Service.

The Challenge

The tower’s height, complex structure and location within the centre of an active airport created significant access, safety and logistical challenges.

Access to the external structure was extremely restricted, with operatives limited to small hatches within the control room soffit. The Air Traffic Control Service also had to remain fully operational throughout the project, placing strict limitations on working areas and access windows.

Conventional exclusion zones could not be established at the scale normally associated with industrial preparation and painting works. As a result, dust, paint and other foreign object debris had to be carefully controlled to prevent materials reaching aircraft, vehicles or operational areas below.

At 87 metres above ground level, changing weather conditions presented a further challenge. Wind speeds and wider conditions required continuous monitoring to ensure work could be undertaken safely while making maximum use of the available working windows.

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Our Response

Working alongside Morgan Sindall, Vertical Access developed a specialist rope access and containment strategy that allowed the maintenance works to be undertaken safely within the highly controlled airport environment.

Rope systems were pre-rigged across the tower to provide efficient access to the work areas and reduce the time required for operatives to move into position. The systems were also configured for rescue, with dedicated rescue provision maintained throughout the works.

To improve efficiency and reduce physical fatigue associated with repeated access to the 87-metre structure, Harken PowerSeat powered ascenders were introduced for rope access personnel and material hoisting.

One of the most significant challenges was containing debris generated during preparation and painting. With the airport remaining fully operational, establishing a conventional exclusion zone large enough to eliminate the risk of dust or paint reaching operational areas was not possible.

In response, the team designed and fabricated bespoke suspended work habitats known as FOD PODs. These enclosed working areas could be positioned around sections of the tower, allowing operatives to undertake preparation and coating works while containing dust, debris and paint within the immediate work area. The habitats also helped control moisture levels during coating application.

The FOD PODs were suspended and repositioned as the works progressed, with Harken powered ascenders used to assist with hoisting them into position for each shift.

Within the controlled work areas, corroded steelwork was mechanically prepared using bristle blasters and needle guns to BS EN ISO 8501-1 Preparation Grade MA/St3. Sherwin-Williams Macropoxy M922M and Acrolon C137V2 protective coatings were then applied, with the specification developed alongside the manufacturer’s technical team to meet the engineer’s requirements and accommodate the restricted working windows.

Quality was monitored through a digital repair reporting system and independent paint inspections, while operatives undertaking the coating works were trained through the ICATS Applicator Training Scheme.

Throughout the programme, weather and wind conditions were continuously monitored, allowing the team to maximise safe working periods while remaining within the defined operating limits.

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Outcome

The maintenance and protective coating works were successfully completed without disruption to the operation of Heathrow’s Air Traffic Control Service.

The combination of specialist rope access, powered access equipment and the bespoke FOD POD containment system enabled complex industrial preparation and painting works to be undertaken safely within one of the most operationally sensitive environments at the airport.

By containing debris at source and adapting the access strategy around the tower’s restricted access points and available working windows, Vertical Access was able to deliver the required maintenance while protecting the airport operations continuing around and below the worksite.

The project delivered the required protective repairs to the tower while maintaining the uninterrupted, safe operation of the Air Traffic Control facility throughout the works.

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