Project overview
The Heathrow Southern Runway Resurfacing Scheme involved the full resurfacing of the southern runway and associated taxiways at Heathrow Airport over an 18 month programme. Delivered during tightly controlled overnight closures, the project required absolute certainty around safety, quality and runway handback in one of the UK’s most operationally sensitive environments.
The scheme introduced a first of its kind two layer working methodology for UK runways, improving interlayer bonding and removing the need for sacrificial ramping while maintaining consistent night by night delivery.
The challenge
Works were carried out during limited night time closures, typically between 10:30pm and 4:30am, followed by a defined curing period before runway handback. Any delay had the potential to directly impact airport operations, placing significant emphasis on planning, reliability and risk mitigation.
The scale of the works, combined with the live airfield environment, required a delivery approach that maximised productivity while maintaining strict control over quality and programme.
Our approach
Associated Asphalt worked closely with Volker Fitzpatrick and Heathrow Airport through Early Contractor Involvement and mobilisation to develop a repeatable, well tested delivery strategy. Trial operations were undertaken adjacent to the runway to validate timings, logistics, resources and nightly outputs within a single shift.
These trials informed a delivery approach typically achieving sections of approximately 60m by 45m per night, providing Heathrow Airport with confidence that the runway could be consistently returned to service on time.
Specialist Marshall Asphalt laying gangs were supported by a dedicated nightly Contracts Manager and on site supervisory team, ensuring clear communication, real time issue resolution and consistent oversight of quality, testing and programme performance.
Scope of works
Works commenced in September 2023 and involved resurfacing the southern runway and associated taxiways within restricted overnight closures on a live airfield.
- Resurfacing the full length of the southern runway (3,658 metres)
- Resurfacing 21 entry and exit taxiways
- Supplying 100 percent of asphalt from onsite asphalt plants
- Nightly production of approximately 750 tonnes, increased to around 850 tonnes following programme optimisation
- Fully approved backup plant and equipment held on site to protect runway handback
Value engineering and innovation
Innovation underpinned the delivery of the scheme. A first of its kind two layer working methodology enabled two binder layers and a surface course to be laid within a single shift, reducing programme duration, improving interlayer bonding and delivering time and cost benefits.
Echelon paving was adopted, with three pavers operating in tandem to eliminate longitudinal joints through hot matching. This approach delivered a smoother finish and reduced the risk of future cracking, improving long term pavement performance.
Digital technologies were also trialled, including Highways Data Systems for automated data capture and SmoothRide technology to support more accurate, autonomous planer control.
Sustainability and environmental considerations
Environmental performance was monitored through regular carbon review meetings with the client and supply chain. One hundred percent of runway and taxiway planings were recycled back into the road network through collaboration with Aggregate Industries and local processing facilities.
The project also incorporated electric vehicles for contract management and progressed trials to transition plant and vehicles to Hydrotreated Vegetable Oil fuel, offering a minimum greenhouse gas emissions reduction of 85 percent.
The outcome
The Heathrow Southern Runway Resurfacing Scheme demonstrates Associated Asphalt’s capability to deliver complex, safety critical works within live airport environments. Through detailed planning, specialist expertise and practical innovation, the team consistently achieved reliable runway handback while delivering high quality, durable infrastructure that supports Heathrow Airport’s long term operational performance.