Background & The Incident
Airside operations are among the most hazardous environments in aviation, with vehicle visibility a critical factor in preventing collisions. In February 2018, a tragic accident at Heathrow claimed the life of John Coles, a long-serving British Airways (BA) employee, when a BA Engineering van collided with another airside vehicle at night.
Investigations revealed that the van was difficult to see amid the visual clutter of floodlights, signage, and other vehicles. The incident underscored an urgent industry-wide need for enhanced vehicle conspicuity and standardised safety markings.
British Airways Engineering’s Response
BA acted decisively in the aftermath:
- Strategic Fleet Review: Comprehensive assessment of its UK-wide fleet (Heathrow, Gatwick, Cardiff, Manchester, Belfast, Edinburgh, Glasgow, Newcastle, Aberdeen, Jersey).
- Adoption of New Standards: Aligned with and in many cases exceeded requirements of CAP 642, EU 139/2014, and Heathrow’s Operational Safety Instruction OSI 008 (2025).
- Objectives:
- Improve fleet visibility in all light and weather conditions.
- Reduce risk of airside incidents and near misses.
- Ensure consistent, branded livery across all engineering and support vehicles.
- Develop a future-proof compliance model for ongoing regulatory changes.
PVL UK’s Role & Solutions
PVL UK, a leader in high-visibility fleet livery, was selected as BA Engineering’s partner to deliver this transformation. Leveraging its 25+ years of expertise across highways, emergency services, and aviation, PVL UK developed and implemented a tailored solution:
- High-Visibility Reflective Markings: Installed R3B-grade microprismatic materials offering up to 300% greater reflectivity than older films.
- Conspicuity Designs: Applied tailored chevrons, Battenburg patterns, contour markings, and rooftop IDs across a diverse fleet:
- Vans, pickups, maintenance cars
- Ground support equipment (tugs, tractors, baggage carriers)
- Specialist units (fuel bowsers, de-icers, GPUs, motorised stairs/steps)
- Brand Integration: Designs retained BA’s corporate identity while embedding safety conspicuity seamlessly.
- Digital Reporting & Tracking: PVL’s proprietary fleet management app captured before/after photos, vehicle condition, and real-time progress — with automated reports sent directly to BA managers.
Implementation & Complexities Overcome
Scale & Phases
- Gatwick: ~40 vehicles completed within 60 days.
- Heathrow:
- Phases 1 & 2: 170 vehicles (cars, pickups, vans) completed in 57 days.
- Phase 3: 32 complex vehicles (tugs, Luton curtain-siders, baggage trailers) completed in 28 days.
- Total: In total we will have completed 300 vehicles in the UK and a further 60 overseas as part of this project.
Collaboration
- BA Engineering ensured vehicle flow to workshops and rapid redeployment.
- Assured Aviation provided vehicle preparation (cleaning, de-liverying).
- Weekly joint meetings monitored progress and adapted schedules.
Challenges & Resolutions
- Vehicle Availability: A working fleet had to remain operational. PVL mitigated by holding pre-cut kits on site, allowing flexible scheduling.
- Complex Assets: Larger and specialised equipment required bespoke templating and rapid iteration.
- Airside Restrictions: Safety and operational compliance were upheld throughout, with close coordination with BA’s safety teams.
- Working across multiple UK airports
Results & Outcomes
The collaboration produced significant and measurable improvements:
- Enhanced Safety:
- 300+ vehicles across UK airports upgraded to OSI008 standards.
- Independent testing confirmed up to 3x greater night-time visibility compared with previous liveries.
- Incident Reduction: Since rollout, no major incidents involving BA Engineering vehicles have been reported, with fewer near-miss reports linked to low visibility.
- Operational Efficiency: PVL’s reporting app reduced manual administration, saving an estimated 10+ hours of fleet manager time per month.
- Cultural Impact: Reinforced BA’s commitment to safety, supporting employee confidence and demonstrating proactive industry leadership.
- Consistency & Compliance: Fleet now exceeds baseline CAA and EASA requirements, positioning BA as a leader in airside safety.
- Scalability: The programme has been replicated at nine additional BA Engineering bases, with pre-cut kits ensuring minimal downtime during future rollouts.
- Cost Saving: Reduced incidents mean assets need less repairs, saving money on replacement vehicle hire, repair costs and asset downtime.
- Brand Protection: Better visibility of branded assets with less minor scuffs and bumps affecting brand perception.
Conclusion
The collaboration between PVL UK and British Airways Engineering represents a landmark project in airside vehicle safety. Born out of tragedy, it has delivered a proactive, scalable and future-proof solution that:
- Prevents recurrence of similar accidents.
- Aligns with the latest CAA, EASA, and Heathrow OSI 008 safety frameworks.
- Provides a replicable model for other airside operators and airports worldwide.
Our role went beyond a simple supply and fit — it encompassed consultancy, compliance leadership, data-driven project management, and innovation. The result is a safer, more visible, and more resilient BA Engineering fleet, setting a benchmark for airside operations globally.
“BA’s commitment to airside safety has undoubtedly set a pace for other airside operators to follow. At PVL we share this same commitment to vehicle safety and if just one more life can be saved, then we have done our job.” – Nick Broom, CEO at PVL UK.
Since undertaking this project BA Engineering have partnered with us to roll-out enhanced vehicle safety markings on their fleet across the world.
