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.

Hayes Balconies

The scope of our works covered the design, fabrication and erection of 309 fully finished balconies.

The project comprised of 471 residential units, a 119 room hotel, a 127 room aparthotel as well as a significant retail area. The project also includes a Sky Pool and a Life Box in which London’s arts organisations will be able to display public art. This particular area will also become a new public square for the town centre. The community also benefits from the production of a Police Liaison Office and a Management Office, both for the town centre.

The Hayes Central Project is a major regeneration of a current Brownfield site.

Nido Spitalfields

We were asked to supply and erect the structural steelwork, metal decking and off/on-site intumescent coatings for this 7-storey office block with an adjacent 35-storey student accommodation building.

The top three floors at one end are a glazed steel frame, while circular structural support columns were required from basement to third floor, to form a spacious entrance foyer.

We undertook detailed pre-planning to simplify the installation process and reduce risks associated with working at such height. To minimise the number of crane lifts, reduce risk to the programme and simplify installation of the structure, many of the steel components were constructed as prefabricated assemblies and have had their connections designed to access from within the footprint of the building to avoid the need for external access at such height. Due to the complex nature of certain elements of the work, we used our own in-house erection department for the entire project while our sister company, Bourne Engineering, were responsible for the steel-to-steel connections.

Strata SE1

Strata is London’s tallest residential tower and home to more than 1,000 residents. The building was one of the world’s first to incorporate wind turbines within its structure and Bourne Steel supplied the tower’s steel wind turbine enclosure.

The roof essentially cuts the building at an angle, resulting in a geometric shape which made the steelwork a challenge to construct. This coupled with the sloping roof level, formed by an angled elliptical concave surface; a vertical concave surface and two vertical convex off-set surfaces -with three circular openings for the wind turbines, makes this a truly unique structure.

The complex geometry of the roof meant the steel frame had to be 17m high, with four curves and six elliptical shaped curves made out of circular hollow steel sections. The curved members are joined with 66 members forming the surface to fix cladding. The structure also has 400 secondary steel brackets, which were welded to tight tolerances. The elliptical openings for the wind turbines were formed from a total of 30 curved hollow sections, all of which were set out in Bourne’s fabrication shop using electronic survey data to ensure accurate positioning.

The Cube

The Cube is a world class building which dominates Birmingham’s skyline. Bourne Special Projects was commissioned to produce two structural steel elements, the ‘crown’ and iconic ‘fretwork screen’.

The two-storey high ‘crown’ features four overhanging wings, one in each of the building’s four corners. The angular sections were achieved by forming 30+ pre-fabricated components from a 3D model under highly accurate workshop conditions. These were delivered to site in one piece and bolted onto the core structure using two tower cranes positioned on opposing sides of the building.

The ‘fretwork screen’, nicknamed the “Tetris” which starts at level 12 and continues to the top of the building, spans the north-western elevation. Remarkably, there is no single uninterrupted line running vertically or horizontally.

Suspended from a 52m truss, spanning the outer edge of the building, the ‘fretwork screen’ is secured to a series of movement joints allowing for expansion and contraction.

Gasholders London

Bourne Steel were appointed to re-erect 3 former gas holder frames within the 67-acre redevelopment site at Kings Cross.

These gasholder frames date back to around 1860-1880 and consist of cast iron columns with wrought iron trusses. The columns were dismantled and specially restored (by others) to then be re-erected as part of the planning requirement for the Kings Cross development. They are now used as an independently standing feature structure built around three new circular residential blocks that contain 144 apartments, a gym and spa, roof top garden and screening room.

The re-erection was made more complex as the residential buildings were constructed first, so the original dismantle column support frames could not be used to re-install the columns.

Due to the fragility of the cast iron, specialist pivot frames were developed to move each column from a horizontal transport position to the vertical position for installation. These pivot frames allowed for adaption to the varying columns lengths and diameters of each column.