Described as “the most logistically challenging construction project ever undertaken in the terminal”, the new mezzanine floor in the International Departures Lounge at London Luton Airport has officially opened and is now in full operation.
Ryebridge worked with the LLA development team to deliver the project, with collaboration from designers, structural engineers, sub-contractors, airside operations, airport security, airport technical services, terminal duty managers and airport concessions.
With LLA continuing to expand and the terminal becoming busier and busier as the demand for flights increases, it was recognised that the space in the lounge was becoming increasingly restricted, especially during peak periods when passengers found themselves uncomfortably rubbing shoulders and without sufficient seating.
There seemed to be no obvious way to increase the capacity without impacting on the customer experience, risking health and safety and affecting live terminal operations.
Building out was simply not possible, so it was decided to take advantage of the high level spaces above the second floor IDL and build a new 675 sqm mezzanine level supported by a steel structure coming up from the baggage area and through the ground floor check-in area.
The new floor dramatically increases the lounge capacity while also providing more access to food, drink and other facilities, with the creation of a new restaurant alongside.
The biggest challenge was constructing this project in a live airport environment, with all of the associated pressures and demands to take into account.
Because there was no room for machinery in the narrow spaces in the baggage area, some of the excavation work was carried out by hand, adding to the challenges faced by Ryebridge.
The foundations for the 18m steels were increased to make them more structurally robust and penetrations in the floors and ceilings took place at night, ensuring the steels could be set in one shift after being transported into the empty check-in area.
Most of the other works also took place at night to avoid disruption caused by noise and dust, and because of the risks posed by carrying out major construction work in an active terminal.
Challenges included reducing the security inspection area, ensuring that baggage handlers could operate adjacent to works and have access to baggage chutes, and preventing vibration and dust from operations interfering with the baggage trolley system.
Once the new floor had been created they poured concrete and screed, and completed shell and core works including stairs, lift, air-handling units, a new window and balustrade, and mechanical and electrical services.
The concrete works were significant as getting the material in required a pump system with the only means of access being through the roof.
Ryebridge planned these works for the quiet time between Christmas and New Year, which provided the largest night window at the terminal.
As the works are classed as airside so access for material and waste away was challenging. All construction material was delivered onto a bespoke scaffolding platform during the day, ready for the team to use at night and replace with any waste which would be removed on days.
Ryebridge managing director Sean Scully said: “This was an extremely complex and technical project, and I would like to thank all of the team for carrying it out so efficiently.”
As part of the works, Ryebridge also stripped out the former Frankie & Benny’s restaurant, with the unit to be fitted out for a new concession now handover has taken place.
