Modular Aviation Fuelling Station: Full Design from Concept to As-Built

An aviation fuelling station leaves little room for improvisation — literally. When the entire station must fit inside a modular container envelope, every pump, valve, filter, pipe run, and cable route competes for the same space, and the layout must still satisfy aviation fuelling and fire safety codes, operational access, and maintenance reality.

TEBIN delivered the full design of a modular aviation fuelling station for an airport project in Germany, across the German HOAI work stages LPH 1 through 5 — from initial concept evaluation to execution design — with documentation carried through to As-Built. Andrii Sheronov led the project as Project Manager.

From brief to buildable concept

TEBIN developed the full station concept from the initial brief through to final design, engineering all equipment placement within the modular container constraints while ensuring strict compliance with aviation fuelling and fire safety codes.

Modular thinking changes how a design develops. In a conventional building, a congested layout can often be relieved by adjusting the architecture. In a container station the envelope is fixed from day one, so spatial conflicts must be resolved by engineering: rearranging equipment, rethinking routing, and proving access — not by asking for more room.

How was the equipment fitted into the module?

TEBIN coordinated the placement and interconnection of all mechanical, electrical, and instrumentation components within the module envelope, optimizing the spatial layout to meet dimensional, access, and maintenance requirements.

In a station this compact, maintenance access is a design deliverable in its own right. A component that cannot be reached, isolated, and replaced within the container is a future operational problem, so serviceability was reviewed alongside the process design rather than after it.

How was the bottom loader integrated?

The bottom loader is where the station meets the refuelling vehicle, and its integration is as much structural as it is mechanical. TEBIN engineered the installation and positioning of the bottom loader unit relative to the container, including the structural interface design, hose routing, and operational clearance, in accordance with the applicable standards.

Designing the fuel path from storage tank to aircraft

TEBIN developed the end-to-end fuel delivery process, from the storage tank through the station to the aircraft. The process design tied the equipment selections, layout, and controls into one coherent operating logic, so the station works as a fuel delivery system rather than a container full of individually correct components.

One coordinated delivery

The project was managed from concept through to As-Built, with coordination across the structural, electrical, instrumentation, and vendor disciplines to deliver a fully integrated modular fuelling solution designed for compliance with the applicable codes. The complete documentation set — piping and instrumentation diagrams (P&IDs), general arrangement drawings, isometrics, support drawings, and equipment schedules — was produced across all project stages.

Project outcome

The project shows how specialist fuel infrastructure can be delivered as a compact modular product without losing engineering rigour: one container, a complete aviation fuelling process inside it, and a documentation trail that runs unbroken from the first concept sketch to the As-Built record.