Metropolitan Police Headquarters


Situated on Victoria Embankment and built in the 1930’s, the Curtis Green Building has been transformed into a “modern, well equipped and efficient new headquarters” for the Metropolitan Police.

Bourne Steel were contracted to install 620 tonnes of steelwork, intumescent coated to six different environmental conditions, with 4,300m2 of metal decking.

The existing front and side façades of the building have been retained and the rear of the building infilled with new steelwork. The steelwork commences with sections in the two lower basements. The refurbishment steelwork within the existing structure involved seven floors of infill steelwork, stiffening steelwork, and a complex jacking system to facilitate existing concrete columns being removed.

Above the seventh floor are two new floors of steelwork.


At 150m high, Highpoint is one of London’s tallest residential buildings and accommodates 457 apartments over 47 storeys.  Bourne Steel was selected to erect a four pronged steel crown on the uppermost level, designed as an integrated architectural and structural system supporting the balconies below via a series of vertical Macalloy bars.

The crown has only 24 main structural steel components, but it was essential that once each component was lifted up onto the roof, they all fitted perfectly. Therefore, a trial erection was undertaken before taking all the components to site. The trial erection was done in such a way as to replicate the actual erection even though it was performed at ground level. This went as far as marking out a space around the crown, identical in size to the top of the tower enabling us to work out the best position for MEWPs, bearing in mind that space was very tight on top of the tower.

As each and every individual steel component was installed, everything had to be continuously surveyed for uplift, sag and the correct geometry, with the trestle’s jacks then adjusted accordingly.

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.

Farringdon Station, Integrated Ticket Hall

The redevelopment of Farringdon station was part of the ThamesLink programme. The Bourne Group delivered the station’s new integrated ticket hall that included under pinning the existing bridge, refurbishing Turnmill Street ticket hall, and installing new roof lights.

The package included the supply and installation of cladding, glazing and louvers; the refurbishment of the existing Grade II listed station building and construction of the new north train shed roof (featured separately).

The structural steel package delivered to Farringdon earned the Bourne Group the 2012 Construction News Steel Specialist Award. What’s more, the project was also shortlisted at the 2012 Structural Steel Design Awards.

Brighton Dome

Structural steelwork was used to sustain and modernise this 200 year old, prestigious Grade II listed building.

The project involved the removal of two proscenium columns, which had been added in an earlier refurbishment in the 1930s. The new work involved a temporary steel frame to support the existing timber Dome and 1930s trusses, then transferring the loads by jacking onto the new steel frame. All the temporary steelwork had to be manhandled into the existing buildings and then erected from inside.

Pre-loading of the new elements and jacking of the existing structure prevented excessive deflections. Other alterations, such as forming openings in walls were dealt with by maintaining existing load paths and spreading stress concentrations through box frames or spreader beams to ensure that the overall load distribution was not significantly altered. Parts of the steelwork that had been dismantled, together with some of the temporary support steelwork, were re-fabricated and incorporated into the new permanent works.

This project and its team received a commendation in the 2003 Structural Steel Design Award.

Marks & Spencer

International retailer, Marks and Spencer plc extended their Plymouth store by demolishing a section of the existing structure and constructing four new floors and a plant room. The extra space gave the store a new cutting edge design with free-flow walkways.

We supplied and installed the structural steelwork, decking and on-site intumescent paint to achieve this stylish shopping space.

It was essential that the store continued trading throughout the entire construction period and in order to achieve this we frequently worked outside of store opening hours. With the building situated in the heart of the lively City centre deliveries had to be planned very carefully.

Ikea Wednesbury & Croydon

We designed, supplied and installed structural steelwork, metal decking, concrete topping and intumescent paint for IKEA stores in Wednesbury and Croydon, over a two year period.

The construction comprised an independent mezzanine steel floor within each of the large warehouse shopping centres. At all times the stores continued to trade.

To cause the least disruption possible a majority of pre-assembly was done off-site and only connections and welding took place in store. Furthermore, we used fibre reinforced concrete to speed up the installation of the flooring.

We are delighted that IKEA has recognised the important role we have performed on these projects and are proud to be on its select list of preferred contractors for future work.

Gloucester Quays Outlet

Retail developments are often challenging as more often than not designers can only proceed with primary frames and basic secondary layouts until tenants arrive further down the line. Consequently, anything from shop fronts to M&E and back of house stairs is unknown, which causes late and frequent design changes.

Our work at Gloucester Quays proved to be no exception. As a result we created bespoke teams at the design stage to accommodate late changes and co-ordinate the different demands of the primary and secondary frames so that both could be serviced without detriment to the programme. We also managed the floor decking, on-site intumescent paint and end connection design. Our work not only consisted of constructing the new designer outlet, which required the erection of two large 400 tonne frames, we also installed the steelwork for the concrete car parks spiral ramp and rotunda roof. The roof is a complex circular structure, which was assembled at ground level and then lifted into its final position as one piece.

In addition to the above, we also refurbished two existing grade II listed buildings. All work was done by hand to ensure the retained façade remained untouched. This stunning new waterside, shopping and leisure development incorporates a new designer outlet, waterways museum, antiques centre, multi-screen cinema, historic docks and new bars and restaurants.

Ridham Dock Biomass Power Plant

Ridham Dock Biomass Power Plant has been constructed by CNIM on behalf of MVV Umwelt to supply up to 25MWE of electricity to the local grid through the incineration of old and contaminated wood.

Bourne Steel was instructed by main contractor, Clugston to fabricate, supply and erect 581 tonnes of galvanised main frame steel and crane steel to form the turbine hall, boiler hall, tipping hall, biomass store and administration offices which was supplied with 60 minutes of fire protection via intumescent paint.

Bourne also supplied 108 tonnes of cold rolled rails and purlins, access ladders, walkways, and 2 tonne grab attachments as part of a secondary steel package.

All fabrication was carried out to NSSS 5th edition.

Wilton EFW

CNIM and Clugston formed a joint venture to build an Energy From Waste Power Station on the Wilton International Business Park in Redcaron behalf of SitaSembcorp UK. 

The new facility thermally treats waste to generate 49 Megawatts of electricity and saves 127,000 tonnes of carbon emissions from being created each year by landfill.

Bourne Steel played the major role ensuring this power station, which included a turbine hall, waste bunker, tipping hall, electrical room and an administration block was fabricated to a very high specification with all crane steel being completed to BS EN1090 Execution Class 3 for fatigue design.

Our site team safely and efficiently erected approximately 1,500 tonnes of galvanized structural steel, including fire protected steelwork to the administration offices, as well as 290nr pre-cast concrete panels in an area of England which is notoriously plagued by high winds and extremely cold temperatures, making the working conditions very challenging.