Heathrow Airport replaces ‘jolly green giant’ with new A380 sized firefighting rig
December 23, 2025
Heathrow Airport has begun using a new, purpose-built aircraft firefighting training rig, replacing a decades-old simulator that had reached the end of its operational life after years of intensive use.
The new structure, designed to replicate the scale and complexity of today’s widebody aircraft, is based around the fuselage size of an Airbus A380, the largest commercial aircraft operating at Heathrow.
One side of the rig resembles the A380, while the opposite side mirrors the profile of a Boeing 787, allowing crews to train across multiple aircraft types within a single installation.
According to Heathrow, the previous rig had been “absolutely sweated as an asset”, having been repeatedly set alight for live-fire training over many years.
Often referred to by staff and enthusiasts as the “Jolly Green Giant”, the outgoing structure was a mixed-type mock-up inspired by older widebody designs, including the Boeing 747 and DC-10. Installed decades ago, it ultimately became no longer fit for purpose as training requirements and aircraft technology evolved.
If you've ever spotted a strange looking green aircraft at Heathrow and wondered what it is, it's actually a training aircraft for our @HeathrowFire Service. 🚒
— Heathrow Airport (@HeathrowAirport) July 11, 2018
Nicknamed the Jolly Green Giant, it's made up of the nose of a 747 and a DC-10 tail. #avgeek pic.twitter.com/fbEn5s5bx0
Heathrow’s new A380-inspired firefighting rig: Built for today’s challenges
The replacement rig has been designed specifically to meet modern airport fire and rescue demands and regulatory standards. It supports a wide range of internal and external fire scenarios, including:
- Engine fires
- Landing gear and running fuel spill fires
- Internal cabin fires
- Cockpit and overhead locker fire simulations
These scenarios enable Heathrow’s Airport Fire and Rescue Service to maintain operational readiness and comply with Civil Aviation Authority-mandated training requirements, ensuring crews remain proficient in handling realistic aircraft emergencies.
The new simulator was manufactured in Derby, UK, highlighting the continued role of British engineering in specialist airport infrastructure projects. Rather than arriving as a single structure, the rig was built in multiple cylindrical sections, each around four metres in diameter and up to 14 metres long. Some individual modules weigh as much as 32 tonnes.
Moving an A380-sized firefighting rig is not easy
Transporting the simulator to Heathrow required extensive planning and coordination. The oversized sections were delivered by road, involving multiple agencies including highways authorities, police and airport stakeholders to manage movement and installation safely and efficiently.
Heathrow confirmed the arrival of the new rig in late December 2025, marking the end of service for the ageing predecessor and the start of a new phase in firefighter training at the airport.
For a hub the size of Heathrow Airport, which handles some of the world’s largest and most complex commercial aircraft, realistic and up-to-date firefighter training infrastructure is critical. The move from a legacy, 747-era mock-up to a modular simulator reflecting current-generation aircraft underlines how airport safety systems must continuously evolve alongside fleet modernisation.
While passengers may never see the new rig in action, Heathrow says it plays a vital behind-the-scenes role in ensuring the safety of airlines, airport staff and the millions of travellers who pass through the airport each year.
Featured image: Heathrow Airport
