Project: London Liverpool Street Station

Contractor: Morgan Sindall Infrastructure

Distributor: A Steadman & Son

Product: Filon Supasafe E GRP Rooflights

 

 

Project Overview

London’s Liverpool Street Station is one of the UK’s busiest transport hubs, housed within a magnificent Victorian structure. As part of a major refurbishment programme managed by Network Rail and lead contractor Morgan Sindall Infrastructure, the station required a comprehensive upgrade to its aging roof system.

The remit of the project was to replace all existing rooflight requirements and cracked glazing panels across the vast canopy. The primary objective was to flood the station concourse with more natural daylight while modernising the structural safety and thermal performance of the roof, all while respecting the building’s significant historical heritage.

Challenges

The project presented a unique set of logistical and technical hurdles:

Heritage Matching: A critical requirement was for Filon to match the new GRP profile exactly into the existing historical Trafford Tile profile to maintain the architectural integrity of the Victorian station.

Live Environment: The refurbishment took place above a fully operational station. This required a solution that could be installed efficiently without disrupting the thousands of passengers passing through the gates daily.

Logistical Constraints: Due to the station’s central London location and the scale of the project, site access was severely restricted.

Maintenance Safety: Given the height and scale of the roof, the client required a solution that could withstand inadvertent foot traffic for future maintenance programmes.

Solution

Filon, working through distributor A Steadman & Son, manufactured and supplied custom GRP rooflights specifically designed to meet the project’s high-performance criteria.

The product selected was Filon Supasafe E, a triple-reinforced GRP rooflight grade developed for applications where maximum strength and impact resistance are paramount. To address the logistical challenges, a meticulous delivery schedule was implemented, spanning five separate drops coordinated by a specialist haulier to navigate the site’s constraints.

Liam McGreavy, Operations Director – Rail at Morgan Sindall Infrastructure, said: Filon has contributed significantly to the success of the London Liverpool Street Roof Renewal project. Filon worked alongside Morgan Sindall Infrastructure to make sure the product achieved the specification required for the UK’s busiest station. The clarity of communication and strong technical knowledge allowed all stakeholders to be completely informed on key decisions. Once approved, the product was manufactured quickly, to a great standard and delivered in batches suiting the installation.

Technical Specifications:

Profile: Custom-manufactured to suit the existing Trafford Tile profile.

Safety: Supasafe E offers a 30-year expected period of non-fragility, making it ideal for roof areas requiring frequent access.

Fire Rating: Grade 101 – BROOF(t4) to BS EN 13501 Part 5; SAA to BS 476 Part 3; Class 0 to BS 476 Part 6.

Durability: Features Filon UV Protect weather face protection for extended service life.

Light Quality: The material’s diffusing characteristics ensure even light distribution, eliminating the shadows, glare, and ‘hot spots’ associated with traditional glazing.

Outcome

The installation of Filon Supasafe E has resulted in a transformative aesthetic and functional improvement for London Liverpool Street Station. By replacing the old, cracked glazing with high-performance GRP, the station now benefits from significantly improved light transmission.

This increase in natural light has reduced the station’s reliance on artificial lighting, contributing to the project’s energy-saving goals and sustainability targets. Beyond aesthetics, the project has delivered long-term peace of mind regarding safety; the non-fragile nature of the Supasafe E panels ensures a secure environment for Network Rail’s ongoing maintenance teams.

The successful collaboration between Filon, A Steadman & Son, and Morgan Sindall Infrastructure has ensured that one of London’s most iconic landmarks is well protected and illuminated for decades to come.