Heathrow Airport Completes £100 Million Southern Runway Resurfacing

More than 200 engineers and technicians have finished a major £100 million project to resurface Heathrow Airport’s Southern Runway. The once-in-a-decade upgrade ensures the runway remains in optimal condition to handle over 1,300 daily flights. The project took place over 29 weeks, with nightly work meticulously timed to avoid disrupting the airport's busy schedule.

Why Heathrow Resurfaces Its Runways Every Decade

The Southern Runway’s last resurfacing was in 2014. Since then, the runway has experienced immense wear and tear, with around 200-tonne aircraft landing at speeds of approximately 140 mph, depositing 5-10 kg of rubber on the surface each landing. Such impacts necessitate a resurfacing project every ten years to maintain safety and performance standards.

The resurfacing plan began four years ago, involving investigations, design, procurement, and mobilisation to address the complexities of the project.

The Nightly Race Against Time: Inside the 29-Week Project

Tight Schedule and Planning

For 29 weeks, the resurfacing work took place overnight between 23:00 and 05:30, when no flights were scheduled. Each shift had to be completed before the first aircraft began operations at 06:00. The project was especially challenging given Heathrow's busiest summer on record, requiring precise planning to avoid disrupting peak travel periods.

Key Figures and Logistics

• 850 tonnes of asphalt were removed and replaced nightly.
• 120+ vehicles and equipment were deployed each night.
• 150+ operatives worked on the project.
• The project involved coordination with Airfield Operations, NATS (air traffic control), Security, and Heathrow Engineering.

The engineering firm VolkerFitzpatrick led the resurfacing effort, which began in April and concluded in October.

Major Upgrades Completed

The project included several critical tasks:

• 50,000 tonnes of asphalt were laid on the runway.
• 1,100 runway lights were replaced with energy-efficient LED units.
• Over 7 million meters of grooves were cut into the runway for drainage.
• 22 taxiways and runway shoulders were upgraded, covering an area nearly equal to the runway itself.

Sustainability Efforts in Line with Heathrow’s Green Goals

Heathrow incorporated sustainability into the project by transporting materials to a nearby facility in Colnbrook via rail, reducing road transport. The 70,000 tonnes of old asphalt removed from the runway are being recycled for local road resurfacing projects, aligning with the airport's commitment to environmental responsibility.

Gawaine Yates, Delivery Project Manager, explained: "This resurfacing is part of a £4 billion investment from 2022 to 2026 to enhance Heathrow. Despite the scale and complexity, the work was completed quickly and safely to maintain our high standards and ensure the best possible experience for passengers."

Looking Ahead: Plans for the Northern Runway

With the Southern Runway completed, Heathrow is preparing for its busiest Christmas season ever, following a record-breaking 30 million passengers from June to September. The airport plans to begin resurfacing the Northern Runway in April 2025, taking advantage of the favorable weather conditions.