When it comes to storing and distributing aerospace-grade materials, there’s no room for compromise. At Prologis, we understand that from temperature-sensitive fluids to flammable adhesives, operational precision and compliance are critical - and every minute matters.
That’s why Aerospheres, a global supplier of aviation chemicals, paints and maintenance materials, turned to our team when it came time to consolidate and futureproof its UK operations.
After 35 years operating across multiple smaller units, Aerospheres was looking for a single, modern space to better support its operations and growth ambitions.
The brief was clear: a facility that could enhance efficiency and enable the safe and compliant storage and handling of specialist materials, all within easy reach of key transport networks and the UK’s major airports.
At Prologis Park Hemel Hempstead, we worked closely with the Aerospheres team to adapt a high-spec, sustainable logistics unit into a bespoke distribution hub, providing the business with a new headquarters to call home. Based near M1 Junction 8, the site is in a prime location, offering easy access to London and the South East, as well as strong transport connections, outstanding sustainability credentials, and the flexibility to grow within a single, purpose-built facility.
A Base Build Ready for Take Off
Aerospheres opted for a new 75,000 sq ft, speculatively developed facility, DC9 at Prologis Park Hemel Hempstead, which was under construction at the time. As well as being a last mile location close to London, the park’s sustainability performance and adaptability meant the building could be easily tailored to meet Aerospheres’ technical and operational requirements.
DC9 was built with sustainability at its core. Comprising an all-electric design, BREEAM ‘Outstanding’ certification and EPC A+ rating, the high-performance building not only supports Aerospheres’ sustainability goals, but also helps reduce operational costs over time. Rooftop solar panels were also installed to generate clean power and provide lower energy costs.
Designed with people as well as performance in mind, DC9 features a first-floor terrace, accessible directly from the office space providing outdoor breakout areas to support employee wellbeing. Outside, landscaped spaces include timber seating, secure cycle shelters with green roofs and provision for electric bike charging, creating a modern, amenity-rich environment for the workforce. The result is a space that helps reduce emissions, improves efficiency, and sets a new benchmark for what an environmentally responsible logistics facility can achieve.
Early Engagement enabling Enhancements
Taking advantage of a pre-let agreement for DC9 allowed Aerospheres to influence internal design features and integrate operational enhancements at an early stage, maximising its investment and reducing time and waste throughout the process.
Working as a close and collaborative partnership, the Prologis team spent time understanding Aerospheres’ operations and visiting the existing facilities to make sure that the new unit was optimised and offered full flexibility to meet requirements.
As part of an agreed building enhancements package, additional meeting rooms and a staff amenity area were delivered by our main construction partner, immediately after the completion of the base build.
The company had never moved into a unit of this size before and looked to the Prologis team to provide in-house project management and consultancy throughout the base build and delivery of enhanced works and fit out.
Paul Thompson, CEO at Aerospheres, commented: “Consolidating our headquarters meant that we needed a facility that could not only meet the technical and safety demands of aerospace logistics, but also would support our long-term growth. Prologis was able to give us exactly that. The new distribution centre is not only in a great location for transport and accessibility, but we’ve also had the flexibility to adapt the space to work for our operational needs.”
Martin Cooper, Vice President, Development Management UK at Prologis, added: “By working closely with Aerospheres from the outset, we tailored the design to meet the business’ precise operational needs, delivering a high-quality, sustainable facility that supports the complex nature of the aerospace industry. The result is a consolidated headquarters that provides a modern, efficient workspace for a growing team and growing business.”
Fit-Out, Simplified: The Power of Prologis Essentials
To simplify the move and reduce disruption, Aerospheres chose Prologis Essentials to manage the complete fit-out of DC9 - providing a turnkey solution for everything from racking and mechanical handling equipment to box erectors and chemical bunds.
Working as an extension of their team, we enabled Aerospheres to shape the building’s operational layout from the outset, helping to optimise key areas for the long term and avoid the delays and costs often associated with post-handover works.
Led by the Project Management of Brenden Shildrick, our UK Operations Essentials team became a single point of contact across the entire programme - streamlining procurement, reducing lead times and ensuring all fit-out elements moved in sync. This joined-up approach saved time, reduced complexity, and meant Aerospheres could focus on operations while our team handled the detail.
Prologis Essentials delivered a series of targeted enhancements, including:
- Design and installation of a compliant flammable chemical store into the main warehouse space, eliminating the need for external cabins and freeing up valuable floor space.
- Aerosol storage, which had previously been difficult to manage operationally, we developed a high-bay racking system fitted with pick-friendly cages to improve access and streamline operations.
- Our racking design, which maximised the internal height of the building to increase capacity, improved space for workforce and stock movement and created a safer, more scalable layout tailored for fast delivery.
- We supported with the procurement of critical Manual Handling Equipment including forklifts and worked to bring all elements, from workspace design to compliance, together.
The result is a fully compliant, well-organised, modern facility that allows Aerospheres to operate more efficiently and scale with confidence.
The project was carried out collaboratively to ensure alignment and we worked alongside Aerospheres’ leadership and parent company to manage the enhancements as part of a single, joined-up plan. This approach meant we could deliver cost and time savings without compromising on scope.
The Essentials platform enabled the internal function of the new unit to be built with the future in mind. From fast-moving product areas to long-term storage strategies, every decision was made to support growth, speed and operational agility.
Yohan Ferdinando, Operations Director at Aerospheres, said: “All the way from our enquiry to fit-out, the Essentials team made the process stress-free, giving us complete peace of mind that we would have everything we needed as we made the move to our new headquarters. Having a single partner managing everything from racking to the office fit-out meant that we could focus entirely on our operations without worrying about coordination or delays.”
Danny Bostock, UK Lead at Prologis Essentials, added: “As with every Essentials project we support, the goal here was to make Aerospheres’ move as simple as possible. By working as an extension of their team, we helped get the new headquarters up and running quickly and made sure that every element of the fit-out aligned exactly with the team’s operational business goals.”
The Sky’s the Limit
Having a people-first environment critical and Aerospheres needed a logistics park that would blend wellbeing and community with high-quality workspaces. Prologis Park Hemel Hempstead benefits from our PARKlife initiative, which focuses on creating spaces and places where our customers' businesses can thrive. This includes landscaped green areas, walking routes and outdoor seating designed to promote physical and mental wellbeing whilst at work. A dedicated on-site property management team is also available to ensure that the park is maintained and looked after.
Aerospheres wanted to ensure that its workforce could conveniently commute following the relocation. To make the move easier for the team, we partnered with Zeelo to provide an on-demand bus service across the park and we also offer a lift-sharing platform to make commuting both easier and more sustainable.
Whether you’re consolidating operations, planning for future growth, or raising the bar on sustainability, we’re here to make it happen with buildings that perform and a team that delivers.
From layout and logistics to forklifts and final fit-out, we’ve got you covered. Speak to us today and discover how Prologis can support your next move.