Protecting the environment: Luton Airport Fuel Upgrade

When it comes to chemical and fuel storage, safety and environmental protection are non-negotiable. Strict regulations are in place to ensure that any potential spills are contained and prevented from polluting the ground or nearby watercourses. That’s why it’s essential for every part of a storage facility — from floor slabs to containment walls — to be completely fluid-tight.

The Challenge

Castle and Pryor were brought in to upgrade the fuel facility’s forecourt at Luton Airport and the storage bund areas. The goal? To ensure every surface, joint, and wall could withstand the demands of a busy, 24/7 fuel operation while meeting the latest environmental protection standards.

What Is a Bund?

A bund is essentially a protective barrier — a secondary containment system built around storage tanks or fuel areas. Usually made from concrete or brick, it acts as a safety net, holding any leaked liquid before it can reach the soil or water.

By regulation, a bund must be able to hold at least 110% of the volume of the largest tank it surrounds — giving complete peace of mind in the event of a spill.

Our Solution

Our specialist team began by removing all failed sealant from joints and replacing it with a fuel-resistant material, restoring the integrity of every joint. We also repaired cracks and damaged concrete areas, cutting out and resealing where needed to make the slabs fully watertight.

Several ironwork surrounds were also showing signs of failure. These were carefully broken out, lifted, and reinstated using a two-part, hot-applied, non-permeable repair material — ensuring long-lasting durability and leak prevention.

Reinforcing the Bunds

The bund walls and plinths — essential for containing any potential fuel spills — were given extra attention. After a deep clean using a high-powered jet washer, the team applied a specialist bund paint to seal all vertical surfaces. This coating forms a tough, impermeable barrier designed to keep any leaked fuel safely contained.

Working Around the Clock

Because the forecourt operates 24/7, careful planning was crucial. Our team worked in phases to avoid disrupting fuel deliveries or site operations, ensuring the facility remained open and fully functional throughout the project.

Access to the bund areas was also limited, meaning every piece of equipment had to be carried in by hand. Despite the challenge, the team maintained strict safety standards and completed the works efficiently and on schedule.

The Result

Thanks to Castle and Pryor’s expertise and attention to detail, the facility now has a robust, compliant, and environmentally secure containment system. The upgraded forecourt and bunds not only meet the latest regulations but also provide long-term protection for both the site and the surrounding environment.

This project is a great example of how Castle and Pryor deliver high-quality, safety-focused solutions — even in complex, live working environments.

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