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LAKESMERE - Express Off-Site Solution For New London Rail Station

The transformation of Londonís existing Farringdon Station into one of the cityís busiest transport hubs remains firmly on the right track thanks to the effective use of partnering and an innovative off-site roofing solution devised by national building envelope Lakesmere and its supply chain partners.

Working in close collaboration with main contractors Costain and Laing OíRourke, client Network Rail and specialist steel contractor Bourne Steel, Lakesmere used the latest 3D design and logistics planning software to demonstrate the significant cost and time savings that could be gained by utilising off-site construction techniques in the creation of the stationís new train shed roof canopy.

The attractive roof canopy of the stationís train shed, which is being extended and upgraded to accommodate the longer trains that serve the Thameslink and Crossrail routes, has been created using fully integrated bespoke roof modules that were designed and developed through close collaboration between Lakesmere and steel contractor Bourne Steel. Complete with structural steel supports, zinc cladding, louvers, glazing and rooflights installed by Lakesmere, the modules were manufactured and assembled off-site before being checked at ground level and lifted into position next to a similar sized bullnoses, which has also been fabricated off-site. The two sections, which are too large to have been transported in one piece, were then joined together on-site and crane-lifted into position on the roof. The huge steel structures into which the roof modules have been installed are also some of the largest of their type to have been successfully transported in one piece by road.

As the station remained operational throughout the construction programme, this off-site solution has helped to minimize the disruption to the rail network and general pubic as well as creating a safer and smaller site footprint where the need for working at height and the use of full scaffolding was significantly reduced.

As part of its contract, Lakesmere was also appointed to install trapezoidal glass roof lights to the main station ticket hall roof and insulated panels and rainscreen cladding to the 38 metre long access bridge located at the rear of the ticket hall.

Farringdon Station is the latest project to benefit from Lakesmereís established expertise in the off-site construction market and follows the completion of St. Pancras Renaissance Hotel, where the Lakesmere team successfully delivered an innovative off-site cladding solution through the development of Thru-Wall. Created in conjunction with supply chain partners Hemsec Installations, this innovative new modular structural insulated panel system proved to be ideally suited for use on a site with such an extremely tight footprint and in particular, on the east elevation of the new hotel that is situated just 300mm from the external wall of the existing St Pancras Station.

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