A new link bridge, installed at Heathrow Airport in November is an early example of a progressive shift of emphasis by BAA from construction on-site to manufacture off-site. The bridge connects the Phase 1 development, completed 21⁄2 years ago, with the new Phase 2 departures lounge building at the end of Pier 5. It is designed as a two-storey segregated bridge-link, with outgoing departing passengers travelling at the lower level, while arriving passengers travel at the upper level.

The approach to off-site prefabrication was a MACE-inspired idea allowing parallel construction processes to take place whilst still allowing the vital airside road underneath the link bridge to remain fully operational while the link bridge was being constructed elsewhere.

Roger Preston & Partners’ involvement included the design of the M&E services within the link bridge itself and the connecting infrastructure services between the Phase 1 and Phase 2 developments. The bridge conveys the necessary chilled water, heating water (HTHW), mains water, communications, fire alarms and specialist electronic services between the two buildings.

RPP were first commissioned as framework consultants to BAA in 1996. Such is the level of work and variety of projects, the company have staff permanently based at Heathrow. The wide remit for framework consultancy includes areas such as vertical transportation, security systems, IT infrastructure, fire engineering, building management and environmental systems.
The bridge link is approximately 333 tonnes in weight (450 tonnes with its temporary supports and moving carriers), and is approximately 52m. long, 6m. wide and 8m. tall. It took about 35 weeks to build at the remote Zulu stands at the southern side of Heathrow airport, and took about one hour to travel the mile to its final location on the night of Monday 28 October 2002.

The bridge link was constructed safely at ground level before being transported to its final location between the two buildings and lifted 5m above the airside road.

The internal services were in part also prefabricated before being assembled in the link bridge, the integrated services booms were made at Crown House’s Wolverhampton factory incorporating chilled beam, pipework, air ducts, cable ways, lighting and ceiling panels. Other services within the Link bridge included perimeter heating and fire alarms. Services were tested ready for final commissioning once connected to the main building infrastructure.

The bridge itself was fully fitted with all glazing, flooring, finishes and, at the upper Arrivals level, a 28 m long people mover.

Nigel Cole, Production Manager at MACE has written to the Pier 5 Phase 2 Team thanking them for their efforts: “The design and methodology of assembly was a new way of working for some, but its success has proven we can all work as an integrated team to deliver a very substantial "lump" of the project….

Congratulations to everyone who played a part in this success. It may not be realised now, but it has instigated a major change in the way construction implementation will be viewed on all future projects.”

Cath Shuttlworth, BAA Project Leader, has been quoted in BAA’s Heathrow Skyport Newspaper November 2002:

“We are pleased the complex operation to move the link bridge into place went so smoothly. A huge amount of planning and teamwork among Heathrow staff made sure the transfer was a success.

The bridge forms a vital part of the overall project which, on completion, will significantly enhance passenger facilities at Terminal 3.”

For more information, contact Jeffrey Wood on 01628 623 423 or at j.wood@rpreston.com