Combining design, construction, ground engineering, specialist mechanical and electrical expertise we completed Terminal 2B, delivering a satellite building that is linked to the main terminal through an underground tunnel.
At £592 million, constructing the new satellite terminal was one of the largest airside projects in Heathrow’s history and now provides pier-served tunnel links to the main Terminal 2.
Combining expertise from across the Group, we seamlessly provided a diverse range of design and construction solutions including:
Balfour Beatty Ground Engineering: Our in-house piling business, installed over 2km of diaphragm walls, 700 piles and 160 plunge columns to support the new terminal building.
Balfour Beatty Kilpatrick: Supplied, installed, tested and commissioned all the mechanical and electrical works including, public health services, all airport operation systems, information communication systems, lighting control, building management, supervisory Control and Data Acquisition system (SCADA), passenger lifts, escalators and conveyors. By prefabricating the plant room and other mechanical and electrical components at our Off-site Solutions facility we delivered Phase 1 of the project ten weeks ahead of schedule, removing 115,000 hours of work from site and mitigating safety risks by reducing hot works. A significant amount of on-site working was also saved during Phase 2 of the works through further pre-fabrication initiatives which also contributed to a reduction in the overall project timeline.
Construction: Design and build of phase 2 provided capacity for a further 16 pier-served stands including mix mode stands that can receive A380 jets.
contract value
more carbon-efficient than the old building
new stands capable of receiving A380 aircraft
The project presented various design and construction challenges, including working in a live airport environment, buried critical services and managing complex ground conditions. To address these, during Phase 2, a mixed top-down and bottom-up construction approach was adopted, allowing the steel frame to be erected while excavation continued underneath, saving approximately six months in construction time.
Innovative engineering solutions, such as the largest diaphragm wall in Europe at the time, were implemented, utilising over 165,000 cubic metres of reinforced concrete. This technique minimised excavation volumes, provided additional usable space, and enabled faster construction. Extensive use of temporary ground anchors allowed for large clear excavation areas, eliminating the need for internal propping and facilitating parallel construction activities. These strategies resulted in substantial excavation and material savings, ensuring the project was delivered on schedule and within budget. The satellite pier now features 16 new aircraft stands, retail space, and an extensive basement for future baggage handling and transit systems, highlighting the project’s scale and complexity.
The integrated design and construction team had a strong focus on safety. As part of our zero-harm initiative, the project team was challenged to eliminate any major catastrophic events and any serious injuries or fatalities. Several Fatal Risk Working groups were established to review potential hazards, risk, and mitigation measures. The drive to reduce site accidents led to many prefabrication initiatives including steel reinforcement cages for over 80% of the reinforced concrete works at the nearby Colnbrook Logistics Centre.
Earthwork generated 680,000 cubic metres of soil, 100% of which was reused, with approximately 300,000 cubic metres providing a clay cap over a former domestic refuse site at the former Hithermoor Quarry in nearby Stanwell Moor. We also recycled over 99% of demolition waste from the old Terminal 2 including concrete, metal, plastic and timber.
As a partner in The Heathrow Sustainability Partnership Construction Training Academy, we provided employment, training and development opportunities for local people. We should also update the start of the above wording so it reads: We also introduced Green Barriers, that provided site-based employees with a safe, clearly marked walking route through the site. This was one of several Balfour Beatty initiatives that was mandated across the airport by Heathrow Airport Limited. This was one of several Balfour Beatty initiatives that was mandated across the airport by Heathrow Airport Limited. Through its use of sustainable construction techniques, the project was given a BREEAM Very Good Rating, the first airport building in the UK to achieve this.
Balfour Beatty is one of those companies who routinely looks for ways to make things better. From what I have seen innovation and safety are clearly embedded in the Balfour Beatty culture.
Steve Morgan
Capital Projects Programme Director, Heathrow Airport Ltd (Formerly BAA)
01:23
Balfour Beatty's Steve Hough, Innovations Director, explains the benefits of producing mechanical pipework and electrical wiring modules off-site. Prefabrication can save up to 30% of programme time on site and increases workforce safety. Subtitles available. #expertengineers