Site Decarbonisation: Keltbray Achieves 100% Electrification at Heathrow Cargo Tunnels

Keltbray, a leading UK specialist engineering and construction services provider, achieved 100% electrification of its Heathrow Cargo Tunnels project, a successful demonstration of electrification in construction.

Keltbray’s electrification strategy ensured that every aspect of work completed on the Heathrow Cargo Tunnels project, including backup power, relied solely on battery technology, eliminating the need for diesel on-site.

The project at Heathrow, delivered by Keltbray’s Environmental Services team, involved asbestos residue removal and concrete repairs. The unique location presented accessibility challenges, navigated through with the use of portable battery technology, allowing Keltbray to deliver a successful completion.

The Benefits of Battery-Driven Construction

Keltbray’s decision to utilise battery-powered solutions on this project had significant benefits, including:

• Increased Efficiency: Battery-driven operations increased the efficiency of Keltbray’s project by overcoming accessibility challenges.
• Emissions Reduction: The absence of diesel resulted in a reduction of greenhouse gas emissions, in line with Keltbray’s commitment to addressing climate change and carbon reduction standards.
• Improved Air Quality: Through electrification the project emitted less pollution directly into the local area, helping to improve air quality and contributing to a healthier environment for workers, airport users and stakeholders.
• Reduced Noise and Vibrations: The electrical equipment used produced significantly less noise pollution and vibrations, reducing occupational health concerns.
• Fuel Cost Cuts: Adoption of electrification lead to a substantial fuel cost reduction.

Strategic Electrification Equipment Selection

At the heart of the Heathrow project’s electrification was a strategic selection of battery-powered equipment:

• Electric Vehicles: Employment of two high-top panel electric vans, two nine-seater electric minibuses, and one small electric van.
• Innovative Tools: Utilising two Hussh pod battery units, nine small battery packs, and an electric tower light.
• Ensuring Reliability: A backup HVO (Hydrotreated Vegetable Oil) generator served as a safeguard, although its intervention remained unnecessary.

These self-contained battery units, including battery packs, Hussh pods, and yellow battery packs from Rite-Power, were especially effective for carbon savings. The two Hussh pods alone saved a total of 22,862 kgCO2e with an average run time of 2,132 hours; an emissions saving equivalent to the energy required to power 2.9 homes for a year. These innovative pods outperformed traditional red diesel generators and resulted in cost savings of £1,911.04.

Transforming the Industry: Electrification as Standard Practice

Keltbray’s efforts in site electrification have been acknowledged by the Construction Leadership Council (CLC), highlighted in their Construct Zero 6^th Quarterly Framework report. Find the full framework here. [Performance Framework Dashboard]

Keltbray’s delivery of electrification on the Heathrow Cargo Tunnels is one part of a wider company move to introduce electrification as standard practice on as many projects as feasible, part of the journey towards net-zero. With the establishment of the Utilities team, electrification on the majority of Keltbray sites has seen fuel generators replaced with Temporary Building Supply (TBS), testament to the pivotal role mains power can play in decarbonisation.

For a comprehensive overview of Keltbray’s decarbonisation efforts, explore our carbon reduction plan. [Carbon Reduction Plan by Keltbray – Issuu]