Swann Engineering Group was commissioned to deliver the refurbishment of a coastal radar tower in Jersey, supporting critical air traffic management operations across the Channel Islands.
Operating within a live aviation environment, the project involved a complete life-extension programme designed to restore the structural integrity of the radar support structure while minimising disruption to operational services.
The works included a full site measure-up survey, structural remodelling, steelwork repairs and extensions, upgraded access systems and the application of specialist marine-grade protective coatings. Due to the exposed coastal location and operational sensitivities of the live radar equipment, the project required careful planning, specialist access solutions and highly controlled installation procedures.
Despite challenging weather conditions and complex island logistics, Swann Engineering Group successfully delivered the project safely, efficiently and in line with all operational requirements.
Project Objectives
The key objectives of the project were to:
- Restore the structural integrity of the radar tower
- Extend the operational lifespan of the structure
- Minimise disruption to live air traffic control services
- Improve future maintenance access and inspection safety
- Deliver full traceability and quality assurance documentation
Scope of Works
Survey, Planning & Engineering
Prior to works commencing, Swann Engineering Group completed a detailed pre-construction survey and coordinated closely with the air traffic control team to align all works with approved outage and weather windows.
Detailed planning was essential due to the operational sensitivity of the live radar equipment and the exposed coastal environment.
Works included:
- Full site survey and structural assessment
- Programme coordination around ATC operational requirements
- Engineering and temporary works planning
- Logistics coordination for island delivery and installation
Steelwork Fabrication & Installation
To minimise working at height and reduce installation time on site, all replacement steelwork and access components were prefabricated and trial-fitted within Swann Engineering Group’s workshops before transportation to Jersey.
Installation works were completed using a combination of specialist cranage, engineered temporary works and rope access techniques to safely remove and replace structural elements within the confined site conditions.
The refurbishment works included:
- Structural steelwork repairs and extensions
- Radar tower remodelling
- Upgraded access systems
- Specialist lifting operations
- Controlled removal and reinstatement works
Surface Preparation & Protective Coatings
Due to the harsh marine environment, corrosion remediation and protective coating systems formed a critical part of the refurbishment programme.
Swann Engineering Group carried out surface preparation under controlled conditions before applying a high-performance marine-grade protective coating system specified for long-term durability in coastal conditions.
Works included:
- Corrosion removal and remediation
- Controlled surface preparation
- Marine-grade coating application
- Coating thickness and quality inspections
Challenges & Solutions
Live Critical Infrastructure
Challenge:
Working adjacent to sensitive live radar equipment required carefully managed shutdown periods and strict operational controls.
Solution:
Swann Engineering Group coordinated all works alongside the ATC team, aligning installation activities with pre-approved outage windows to minimise operational disruption.
Coastal Environment & Weather Constraints
Challenge:
The exposed coastal location experienced frequent high winds and unpredictable weather conditions, impacting lifting operations and installation schedules.
Solution:
Flexible programming and specialist temporary works systems allowed the team to adapt safely to changing weather conditions while maintaining project progress.
Island Logistics & Restricted Access
Challenge:
All materials, equipment and consumables had to be transported to Jersey and installed within a confined working area with limited access routes.
Solution:
Swann Engineering Group implemented carefully staged deliveries, off-site prefabrication and precise lifting operations to streamline installation and reduce on-site congestion.
Quality Assurance & Compliance
Throughout the project, Swann Engineering Group maintained strict quality assurance and compliance procedures, including:
- Full inspection and test documentation
- Material certification records
- Bolt installation records
- Coating DFT inspections
- As-built drawings and O&M documentation
- Comprehensive lifting operation traceability
Outcome
The radar tower refurbishment was completed safely and successfully despite challenging weather and logistical constraints.
The project significantly extended the operational lifespan of the structure while improving future maintainability and safe access for inspections. Through careful planning and coordination, operational downtime for the air traffic control client was kept to an absolute minimum.
Swann Engineering Group delivered a fully refurbished radar support structure capable of withstanding the harsh marine environment while meeting all operational, safety and compliance requirements.
