East Midlands Airport

Brief Summary:

CHJ Mechanical Ltd successfully delivered the full design and build of new mechanical services for the immigration hall and offices at East Midlands Airport in Derbyshire. The £270,000 project included energy-efficient air conditioning, ventilation, and domestic water systems designed for performance, comfort, and reliability. Completed safely within a live airport environment, the works were delivered collaboratively, on time, and ready for the busy spring travel season.

Overview

At CHJ Mechanical Ltd, we were proud to be appointed to design, supply, and install the complete mechanical services package for the new immigration hall and first-floor offices at East Midlands Airport.

The project aimed to create a comfortable, energy-efficient environment for staff and passengers while ensuring system reliability, ease of maintenance, and long-term sustainability. Our works included new Daikin VRV heat recovery air conditioning systems, air handling and heat recovery ventilation, domestic hot and cold water services, and all associated automatic controls and drainage systems.

Delivered under a full design and build contract, the project required detailed technical design, precise on-site coordination, and strict adherence to airport security and operational protocols. With a contract value of £270,000, the works commenced in December—during the quieter winter period—and were completed in February, well ahead of the spring travel season.

This project highlights our ability to plan and execute complex engineering works within live, high-security environments while maintaining CHJ Mechanical Ltd’s core values of sustainability, efficiency, reliability, and collaboration.

Challenges

Working airside at an international airport brought unique challenges that demanded thorough planning, adaptability, and close collaboration with the airport authority and other trades.

1. Operating within a live airport environment:
All works were undertaken airside, which meant that every operative, vehicle, and item of equipment had to meet strict security requirements. Specialist background checks, permits, and training were required before work could commence, and all activities were subject to the airport’s operational controls. Maintaining smooth coordination between our team, airport staff, and other contractors was critical to the project’s success.

2. Space and coordination constraints:
With exposed services in the immigration hall and offices, all pipework, ductwork, and containment had to be installed with precision and visual appeal. The absence of suspended ceilings meant that every visible element—air conditioning cassettes, duct runs, and trays—had to be carefully planned, aligned, and finished to the highest standard.

3. Maintaining airflow performance and comfort:
The immigration hall required a large volume of conditioned air without creating drafts or noise disturbance. Achieving this balance in a busy open environment required creative thinking and a bespoke ventilation solution.

4. Multi-trade collaboration:
CHJ Mechanical Ltd worked closely with the main contractor, electrical engineers, and building fabric specialists to ensure that all systems were seamlessly integrated. This was essential not only for programme delivery but also to achieve a neat and professional finish within a highly visible public space.

Our Solution

CHJ Mechanical Ltd delivered a full turnkey mechanical package, from design to commissioning, integrating energy-efficient technologies and practical installation techniques to meet the airport’s operational and sustainability requirements.

1. Air conditioning installation:
We installed new Daikin VRV heat recovery air conditioning systems to provide both heating and cooling across the main immigration hall and associated first-floor offices. The main plant was positioned externally, with interconnecting services routed on exposed cable tray containment to indoor four-way cassette units.

Due to the visible nature of the installation, every component was planned and installed with exceptional attention to detail. Pipework routes, tray runs, and cassette positions were fully coordinated using detailed drawings and on-site mock-ups to achieve a clean, uniform aesthetic.

2. Ventilation and air handling:
Ventilation to the immigration hall was provided by an external deck-mounted heat recovery air handling unit. To deliver air evenly across the large open space without creating drafts, we designed and installed a fabric air sock distribution system. This solution provided a gentle, continuous airflow while maintaining low noise levels—ideal for a busy public environment.

To the first-floor offices, we installed compact ceiling-mounted Daikin VAM heat recovery units, delivering fresh air and energy-efficient heat recovery throughout the space via galvanised steel ductwork and terminal grilles/diffusers. All ductwork was thermally insulated, with external sections fully weather-protected for durability and performance.

A new extract ventilation system was installed for the toilet areas, designed to meet Building Regulations and maintain a pleasant, well-ventilated environment.

3. Controls and automation:
All systems were integrated into a centralised Daikin control platform, allowing for intelligent management of heating, cooling, and ventilation functions. This ensures optimal energy efficiency, simplified monitoring, and easy future maintenance for airport facilities teams.

4. Sanitary ware, domestic water services and drainage:
We installed new hot and cold water services throughout the new toilet facilities, including pumped hot water return systems for instant availability at outlets. Hot water generation was provided by a new electric calorifier, ensuring reliable and energy-efficient performance. All new sanitaryware and above-ground drainage systems were installed as part of our package, completing the full mechanical installation.

5. Sustainability and energy efficiency:
The combination of air source heat pump technology and heat recovery ventilation provides substantial reductions in energy consumption and carbon emissions compared with traditional systems. By maximising recovered heat and optimising system control, the installation aligns with the airport’s environmental targets and supports the UK’s broader drive toward sustainable infrastructure.

6. Collaboration and safety:
Throughout the project, our engineers worked closely with airport authorities, security teams, and fellow contractors to ensure compliance, safety, and smooth coordination. All site activities adhered to stringent airside safety protocols, and all works were completed with zero safety incidents.

Results

The project was completed on time, within budget, and to a high standard of quality and finish. The new systems provide exceptional comfort, efficiency, and reliability for both passengers and airport staff.

• Energy performance: The heat recovery VRV air conditioning & ventilation systems deliver excellent efficiency, reducing overall energy demand while maintaining precise temperature control year-round.
• Improved comfort: The immigration hall and office areas now benefit from balanced, quiet airflow and stable temperature control, enhancing the working environment and passenger experience.
• Aesthetic and functional design: With exposed services throughout, the final installation achieves both performance and visual appeal, demonstrating CHJ Mechanical Ltd’s craftsmanship and attention to detail.
• Operational reliability: All systems were rigorously tested and commissioned to ensure dependable performance and ease of maintenance.
• Successful collaboration: The project stands as a strong example of coordinated teamwork within a live, high-security environment—achieved safely, efficiently, and to programme.

This installation showcases CHJ Mechanical Ltd’s ability to combine innovative, sustainable technology with practical on-site expertise to deliver exceptional results within challenging environments.

Client Feedback

 ‘CHJ Mechanical demonstrated outstanding professionalism throughout this complex project. Working airside required precision and coordination, and the team delivered a high-quality installation on time and to specification. The new systems are efficient, quiet, and reliable, and we couldn’t be happier with the results.’]