AIRPORT: :Heathrow

ROLE: :Multi-Storey Car Park Refurbishment

YEAR: :2005


Amalga has been involved with projects within the central terminal areas of Heathrow and Gatwick Airports over the past seven years. Amalga's workforce possesses a wealth of knowledge and experience relating to specific constraints and requirements associated with these live airport environments.


A prominent achievement - between March and July 2002, while Amalga was employed by Warings Contractors Limited in Partnership with Taylor Woodrow and BAA - was the project to refurbish the multi-storey car parking facilities there.

While not the largest task in terms of duration or value, the technical demands involved the removal of 4360 concrete cladding panels, (each weighing approx 90 kilograms) from the external facade of the five storey high buildings. Critical constraints included keeping fully functioning car parks open to the public, and removing all cladding from the building via an internal route.

Project Highpoints

Amalga engineered a novel solution to remove the reinforced concrete cladding from facade of the multi story short term car parks by using a set of bespoke lightweight mobile lifting rigs that operated from inside the car parks. Amalga's ingenious solution and careful management of significant Health & Safety hazards resulted in the car parks remaining open to the public throughout the works. Amalga's solution ensured that the job was undertaken quickly, efficiently, in an environmentally friendly manner and above all, safely. The project was delivered to the customer under budget with savings passed back.

Key statistics

  • Amalga devised and engineered a novel solution to remove 4360 concrete cladding panels, (each weighing approx 90 kilograms) from external wall of car parks, via the internal area:
  • 25200 man hours worked
  • 260 training hours
  • 0 accidents
  • Planned cost of £424,000
  • Delivered cost £388,000
  • Result = 8.5% saving to customer


  • Solution included recycling of all waste materials:
  • 392 tonnes of reinforced concrete cladding panels
  • 12 tonnes of cement mortar
  • 4800 metres of timber battening
  • 3.8 tonnes galvanised steel meshing