BJF Group delivered the full replacement of life expired district heating pipework across a live, occupied military estate, installing a modern low temperature hot water (LTHW) network designed for long term performance and resilience. All works were carried out within plantrooms, service tunnels, and confined access areas while maintaining uninterrupted heating and hot water services for personnel throughout the programme.
Client Scope
BJF Group were appointed to complete this essential infrastructure upgrade, building on our strong track record within secure Ministry of Defence environments. Working collaboratively with the client team, BJF supported the refinement of the scheme to ensure technical sequencing, access planning, and installation approaches aligned with the constraints of a sensitive, operational site.
- Fabrication and installation of new large diameter district heating and LTHW pipework adapted to restricted plantrooms and tunnels
- Development of temporary works and bypass arrangements to maintain live heating and domestic hot water (DHW) supplies
- Installation of bracketry, supports, thermal insulation, and external cladding
- Safe asbestos removal, builder’s works in connection and firestopping.
- Pressure testing, flushing, dosing, and balancing of the complete LTHW network
Project Goals
The works formed one of several future phases planned to modernise the estate’s wider heating infrastructure. This phase focused on replacing critical district heating pipework, improving reliability, and preparing the site for future upgrades to boilers, calorifiers, heat exchangers, and associated plant.
- Decommissioning the outdated MTHW system in favour of a safer, more efficient LTHW network
- Replacing degraded pipework, valves, and ancillaries serving key operational buildings
- Maintaining continuous heating and DHW services throughout
- Delivering a compliant, future ready installation suitable for a secure, live secure environment.
Execution & Results
The project required a highly controlled approach due to congested plantrooms, narrow tunnels, and restricted working conditions. Key delivery activities included.
- Careful sequencing and daily coordination with the client to maintain uninterrupted heating and hot water service
- Management of asbestos and undocumented services, supported by thermal imaging and diagnostic surveys
- Use of FLIR technology to trace live pipework, confirm heat loads, and verify safe connection points
- Controlled lifting and manoeuvring of fabricated pipework sections through restrictive access routes
- Sequential installation, testing, flushing, dosing, and commissioning to maintain continuous site operation
- Final system integration and balancing, delivering a stable and efficient LTHW network
Lessons Learned
- Early collaborative design development reduced disruption and accelerated technical resolution
- Thermal and visual digital surveys improved as built verification and minimised rework
- Early validation and conditioning reports key to preventing redesign and programme delays
Summary
BJF Group successfully delivered the replacement of district heating pipework within a highly regulated, occupied estate. Despite complex technical and logistical constraints, the works were completed safely and without operational disruption. The upgraded LTHW network now provides a durable, efficient, and compliant heating solution that strengthens the long term resilience of this critical military facility.