Foundation milestone reached at London Gatwick Pier 6 extension

Global delivery consultants and construction experts, Mace have successfully completed the foundation works for the Pier 6 extension at London Gatwick, a key milestone in the £140 million infrastructure programme. The works were delivered by specialist contractor Bachy Soletanche, in collaboration with consulting engineer WSP. 

Over a two-month period, more than 200 continuous flight auger (CFA) piles were installed using a Liebherr LB24 rig, spanning three distinct piling platform levels. Bachy Soletanche’s in-house design team led the development of the geotechnical solution, introducing value-engineered enhancements that reduced pile length, diameter, and platform depth - cutting material usage and significantly lowering the embodied carbon. 

Sustainability remained a central focus throughout the project. The team exceeded low-carbon concrete targets by selecting a ‘CIII/B’ mix, resulting in a saving of approximately 40 tonnes of CO₂e. Further carbon reductions were achieved by minimising crane usage, saving around 1,500 litres of fuel, and sourcing materials from local, airside-approved suppliers. 

Operating within a live airside environment, the project required meticulous logistical planning and close coordination with multiple stakeholders. Bachy Soletanche adhered to strict safety and operational protocols, including airside permits, crane height restrictions, and comprehensive risk assessments. To enhance safety and efficiency, the team implemented innovative methods - such as replacing hot works with hydraulic rebar cutters. 

Set for completion in 2027, the Pier 6 extension will introduce eight new aircraft gates, enabling 7.5 million passengers each year to board and disembark directly from aircraft. This upgrade will reduce reliance on remote stands, eliminate over 12,000 annual bus journeys, and improve overall operational efficiency. 

John Newman, Project Director, Mace Construct, said:  

“This complex pier extension will add much-needed capacity to London Gatwick whilst minimising the environmental impact. Through working closely with the client team and with our experienced supply chain, we have successfully delivered these foundation works in a live environment, on a very constrained site using the latest sustainable techniques.”  

Richard Wall-Morris, Head of Delivery (Major Projects), London Gatwick said: 

“Bachy Soletanche has played a pivotal role in contributing to the 52% savings in embodied carbon we have been able to make in the design and construction of our Pier 6 extension project. We are delighted the pier extension remains on track to open in 2027, when the eight new aircraft gates will enable millions of passengers to enjoy a seamless airport experience every year.” 

Martin Stanley, Divisional Director – South, Bachy Soletanche said: 

“We’re proud to have contributed to such a significant infrastructure upgrade at London Gatwick. Despite the complexities of airside working, our team delivered safely, efficiently and with sustainability at the forefront.”