FSU BA Hangar Doors

A British Airways airplane's tail in the foreground, with a hangar behind and another plane flying in the clear blue sky above.

Key takeaways

3,792

sq m doors (equivalent to 3 olympic swimming pools)

10

panel configuration for each door system

3

crane precision-engineered lifting strategy

At the heart of British Airways' (BA) operational infrastructure, the BA Fleet Support Unit (FSU) hangar plays a pivotal role in keeping the airline’s fleet moving. In 2024, Mace Construct was appointed under a JCT contract to deliver a full replacement of the north and south hangar doors – originally installed in 1970 – with a state-of-the-art, high-performance system engineered to meet the demands of modern aviation. Spanning an impressive 3,792 sq m, the new installation marks a significant upgrade, enhancing both operational efficiency and resilience at one of the world’s busiest airports.

This technically complex project required the design, manufacture, and installation of two 89m-wide, 21.3m-high door systems, each comprising of ten panels running on five tracks. The works were delivered in two phases to ensure uninterrupted BA operations, with temporary weatherproof screens enabling safe demolition and installation. 

From hydro-demolition robots protecting critical infrastructure to a meticulously planned three-crane lift, innovation and precision were central to our approach. We included time allowances in the programme to mitigate the risk of delays due to the risk of poor weather conditions. Our logistics strategy, coined as ‘just-in-time’ protocols, ensured seamless material flow with zero queuing. 

Collaboration was key, working hand in glove with the BA Property and Engineering Team – as well as the entire supply chain – to optimise project outcomes and minimise the impact of BA operations. Weekly planning sessions, stakeholder workshops, and integrated use of BA’s ‘Gate Manager’ and ‘SNOW systems’ ensured alignment across all teams. Lessons learned from the North Phase were embedded into the South Phase, driving efficiency and reducing risk. We engaged suppliers early in the design phase to ensure feasibility and buildability. 

This project exemplifies Mace’s ability to deliver complex, live-environment infrastructure with minimal disruption – combining technical excellence, stakeholder collaboration, and a relentless focus on safety and quality. 