Supporting HMS Queen Elizabeth Class During Flight Deck Thermal Spray Coating

RVT Group supported HMS Queen Elizabeth Class with vapour control and fresh air during thermal spray coating the flight deck.

Project Overview

In summer 2026, HMS Queen Elizabeth was docked for maintenance that included extensive works to the 280-meter-long and 70-meter-wide flight deck.

HMS Queen Elizabeth Class aircraft carrier is one of the largest and most powerful warships ever built for the Royal Navy. Commissioned in December 2017, this aircraft carrier is part of the UK carrier strike group, with the capability to carry up to 72 aircraft. The carrier features two lifts capable of lifting four F-25 fighter jets from the hangar to the flight deck in just 60 seconds and provides rapid response capability with NATO and allied forces.

Created using AI for illustrative purposes only.

Challenge

The client reached out to RVT Group following our successful support on other projects on HMS Queen Elizabeth Class, and other naval ships across UK dockyards. This particular project included thermal spray coating the flight deck with a high grade surface protection that is highly resistant to heat. This specialist coating is only applied to areas of the flight deck where fighter jets vertically take off/land, generating temperatures of up to 1,500°C.

After a free site assessment was carried out by one our defence consultants, we identified that the project team needed:

1. Effective vapour control to protect operatives and the surrounding environment.
2. Forced fresh air into the space, as the project was carried out under tents, creating a poorly ventilated work area.

Due to the potentially explosive nature of the thermal spray coating, ATEX rated equipment was essential. ATEX is equipment that complies with the European ATEX Directive (2014/34/EC), meaning its suitable for use in potentially explosive atmospheres.

If the vapour was inhaled or absorbed through the skin, workers could be at risk of irritation of the eyes, nose and throat, headaches, dizziness, or nausea. Long term health effects from repeated exposure can lead to the increased risk of cancer, neurological effects such as confusion or difficulty concentrating, vision changes, plus much more.

Suitable PPE was going to be used, however, this is considered the last line of defence against hazards, and an effective engineering control was required to ensure effective control of the paint vapour, and to force fresh, clean air into the space.

Solution

After agreeing the best way to support this project, RVT Group engineers based at the naval site installed the effective, compliant hazard control solution that ensured workers and surrounding environment were protected.

Within the tents, we installed multiple VENTEX® Centrifugal Fan 300M ATEX fans, and a RAVEX® Superfilta, incorporating actisorb carbon filters and paper EU4 filters. This solution then had multiple lines of ducting with capture hoods at the end entering the tent. The cylindrical actisorb carbon filters effectively and safely extracted paint vapour, helping to protect both operatives and the surrounding environment from vapour exposure.

With the project being carried out within a tent and fresh air being a real concern, forced fresh air was vital to displacing any hazardous air. To support with this, we installed a VENTEX® Centrifugal Fan 450S ATEX with a Y piece splitter attached, and two 15-metre hoses leading into the tent. The 450S ATEX fan is our most powerful mobile fan for use in hazardous areas and moves an impressive 20,000m³/hr free air.

Following the installation of our bespoke set up, the client was able to successfully and safely carry out the project.

RVT Group provide a turnkey service that includes design and consultation, training, installation, commissioning, maintenance, and dismantling. We work with teams to ensure the solution is suitable for the environment and the job at hand. We provide bespoke hire solutions that can be modular to what you need, whether is shorter ducting, a larger filter system or a more powerful ventilation system. We have specialist teams familiar with your challenges who will ensure hire equipment performs on the way it was designed and control the hazard adequately within the environment.

We have been a dependable supplier to world-renowned defence organisations for several years now. We work with teams to ensure the correct, modular solution is installed that suits you and your needs. Due to the sensitive nature of our Defence support, we cannot share images of our installs, however, below showcases other ship maintenance, and industrial projects we have supported.