A behind-the-scenes look at the upgrade
The wider programme will transform how passengers move around Terminal 5. Ten vehicles that have reached the end of their working life will be retired, with ten additional cars expanding the overall fleet. The system layout will also move from a linear design to a figure‑of‑eight ‘loop’, allowing for more efficient operations and greater resilience.
Having navigated the challenges of the Covid pandemic, the TTS (track transit system) upgrade is now seen as a fundamental investment in the future of Terminal 5. The project is expected to continue until mid‑2026 and will play a key role in reducing waiting times and easing congestion as passenger numbers grow.
Each of the new vehicles has taken an impressive journey before entering service. Their story begins in Glasgow, followed by sea transport via Southampton to the United States for interior fit‑out. The vehicles then returned to the UK for final checks and fittings in Derby, before undergoing security screening at Colnbrook Logistics Centre.
Over the past year, each car has been meticulously installed into the TTS tunnel overnight. From a grassed area between T5 and T5B, a sliding roof is opened to allow the vehicles to be lifted and lowered into position.
Each installation involves around 10 operatives working both on the airfield and inside the tunnel. With just half a metre of clearance from the concrete lining and a requirement to land each vehicle within 10 millimetres of the electrified guideway, precision and teamwork are critical at every stage.
Take a closer look at how one of these 15‑tonne vehicles is lowered into the tunnel with millimetre‑perfect precision, a remarkable operation that showcases the skill and coordination of the teams involved.
