Heathrow could cut construction disruption after passenger numbers return to pre‑pandemic levels
Industry leaders say off‑site manufacturing at Prestwick and a reassessment of disruption tolerance could speed up airport capital projects as traffic rebounds.
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New Civil Engineer reported on 21 September 2026 that passenger numbers across UK airports have risen back to the levels seen before the pandemic. The recovery has placed capital expansion projects back on the agenda for Heathrow, Gatwick, Manchester and other hubs.
Disruption cost assumptions at Heathrow
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Heathrow infrastructure director Alistair Awcock told New Civil Engineer that the industry operates on the premise that any interruption to airport operations carries a huge expense. He added that this belief explains the strict rules governing construction activities within active terminals.
Airports work from the assumption that if you disrupt the operation, it’s going to be a huge amount of cost.
Alistair Awcock, Heathrow infrastructure director
Awcock explained that Heathrow has identified some capacity in its system to tolerate limited disruption. He asked whether operators would prefer a two‑year programme that runs alongside daily flights or a one‑year programme that concentrates work and accepts a short period of disturbance. He said operational teams have indicated they can live with a year of disruption more readily than a longer, less intense schedule.
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Proposal for a shared off‑site factory
Graham Bolton, global lead for aviation at Mott MacDonald, told New Civil Engineer that a dedicated off‑site manufacturing facility could be built in Prestwick. He argued that such a plant would be able to produce standardised components for Heathrow and other UK airports, reducing the need for on‑site fabrication and the associated operational impact.
Bolton noted that the model relies on high repetition of parts, which is more feasible when a single factory serves multiple airports. He did not provide a cost estimate, but suggested that the approach could lower capital expenditure by cutting on‑site labour and minimising disruption penalties.
Questions this report answers
+Have passenger numbers at Heathrow returned to pre‑pandemic levels?
New Civil Engineer confirmed that passenger traffic at UK airports, including Heathrow, is now at the same level as before COVID‑19. This resurgence means that capital expansion projects are being reconsidered after a period of delay.
+What does Heathrow say about the cost of construction disruption?
Heathrow infrastructure director Alistair Awcock told New Civil Engineer that airports assume any operational disruption brings a huge cost. He said Heathrow is exploring how much disruption it can accept in order to reduce overall project expenses.
+Is there a plan to build an off‑site manufacturing hub for airport components?
Graham Bolton of Mott MacDonald suggested to New Civil Engineer that a facility in Prestwick could produce components for Heathrow and other UK airports. The idea is to use repeatable parts to cut on‑site work and limit disruption.
+What next steps will Heathrow take to reduce construction time?
Awcock indicated that Heathrow will need to finalize planning and secure stakeholder agreement earlier than usual. By agreeing on methodology and closure plans well in advance, the airport hopes to run a shorter, more intensive construction programme.
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