Gatwick Airport Over Deck Car Park

As part of a framework agreement between Gatwick Airport and Galliford Try, Bourne Parking were appointed to design and build an above ground scope of works for the over decking of Gatwick South terminal’s long stay parking Zones F and G.  The single suspended deck car park provides an additional 1,224 car parking spaces and was built to assist with achieving Gatwick’s objective of passenger growth.  The project is our largest and fastest single deck car park to date, with 26,000m² erected in nine weeks.

The car park was designed and constructed with our lightweight steel frame and precast concrete Montex car park system. The project included six pedestrian stair towers and four pedestrian ramps, the latter of which were constructed with a bespoke precast system designed for this building.  The perimeter of the suspended deck and vehicular ramps were protected with our proprietary BourneBarrier system; which provides integral vehicular and pedestrian edge protection; and the stairs and pedestrian ramps were provided with handrailing and balustrading.

The project was logistically challenging, with all deliveries routed through Gatwick Airport’s existing operational public car parks.  To achieve the ultra fast track programme, we utilised four erection teams working concurrently.  Furthermore, the construction methodology was heavily influenced by Civil Aviation Authority and Gatwick Airport  standards, as the site was directly under the main aircraft approach route and adjacent to the end of the runway. The high performance asphalt waterproofing system was also installed in record time, again using multiple teams working in tandem.

Heathrow Airlinks

Airlinks utilise contemporary architecture and technology, and have been developed specifically for 21st Century airports. The units include full acoustic and thermal insulation to ensure a controlled internal environment. What’s more, a unique connector frame allows separate modules to be connected together, to give a walkway indefinite length.

Airlinks have been designed in accordance with Eurocodes BSEN 1990,1991 and 1993, and CE Marked in compliance with BE EN 1090. The concrete floor ensures compliance with SCI P354 “design of floors for vibrations: a new approach 2007” and the Concrete Centre “a design guide for footfall induced vibration”. Airlinks also comply with BAA Specifications.

Airlinks have a robust steel structure crafted to directly receive composite cladding, roofing and glazing. Airlinks are a fine example of lean construction; they contain so secondary steelwork flashings. Building services are fully integrated within the internal fitout: lighting, heating/air conditioning, PA system, fire detection/alarm, interchangeable double glazing, composite cladding, designed to accommodate ramp gradients up to 1 in 20 and spans up to 28 metres.

Heathrow Bus Station

We supplied and erected the structural steelwork for this new Central Bus Station, located in the heart of the world’s busiest airport. The steel frame comprised a series of double cantilevered and portalised frames, located around the perimeter of an irregular shaped canopy footprint.

The frames typically consisted of tapered double cantilever cross head beams supported on hollow section columns. The outer edges of the cantilever cross beams were tied down to the ground using stainless steel tie-rods consisting of spade and fork end connectors.

This is the first structure that many people will see when entering the airport complex and therefore it was essential that great care was taken with the aesthetics of each joint when detailing the connections. Many were fully welded or concealed. This involved complex connections being developed in order to make them ‘visible’ whilst at the same time robust and practical.

To minimise site erection periods we delivered the steel frame to the airport with as much of the frame pre-assembled as possible.

Heathrow Airport Lift Modules

We were asked to provide a lift core to enable easy passenger access. to the Airside Coaching Stations at Heathrow Airport.

These installations are normally complex and timely affairs, as all works are carried out under strict ‘airside’ regulations. The ‘BourneLift’ product provides a fully contained structural lift solution, which can be used in any structure. The modules can be up to 12 floors in height, self-supporting, and can even provide lateral stability to other structures. The lift shafts can be externally clad or boarded, fully insulated and internally lined with high impact resistant finishes, and fully prepared with fixings and running rails – all installed off-site.

Each module is designed to be fully compliant with Building Regulations and Fire Regulations, to enable a simple interface with a wide range of structures.

Heathrow Airside Coaching Stations

We were tasked with the manufacture and installation of a number of transit areas for embarking and disembarking passengers at Heathrow Airport.

Working ‘airside’ at any airport is a complex and challenging task, with deliveries and lifting times severely restricted. So, it was imperative that these buildings were installed without causing any disruption to the 24-hour operation of the airport.

Prefabricated and clad off-site in our factory in Henstridge, the coaching stations were delivered and installed during a 4-hour night window.

The buildings were finished externally with a combination of glazing and a composite panel, and were linked into the existing terminal structure. As part of the integration with the existing terminal, we carried out some refurbishment to the stair areas, which included the installation of a new lift shaft, using our ‘Lift in a Day’ product.

Gatwick North Terminal Rail Interchange

In order to cope with increasing passenger numbers at the UK’s second busiest airport, Bourne Steel was contracted to supply the North Terminal’s new rail interchange.

Costain partnered with Bourne Steel to ensure the erection process was the fastest possible (keeping disruption to a minimum), without jeopardising the quality fabrication needed to deliver such an important project. Bourne Steel delivered the station’s architectural frame, floors, lift shafts and blast proof train enclosures.

To reduce construction time, the enclosures were brought to site fully assembled. This innovative process saw the project erected in just two days, which was imperative given the constant volume of passengers travelling through the airport.