Installation of aerial concourse canopies requires precise coordination of structural steel, roofing systems, and services integration while maintaining station operations. Production rates vary based on canopy design, span width, and installation methodology. Modern prefabrication and modular systems have improved installation efficiency.
Key Statistics:
- Average span: 15-25m
- Typical width: 8-12m
- Height clearance: 4.5-6.0m
- Best practice: 150-200m²/week
- Steel erection: 8-12t/day
- Glazing: 100-150m²/day
- Services integration: 25-35%
- Weather protection: IP65
INTERNATIONAL EXAMPLES
| Country | Station | Area (m²) | Type | Rate (m²/week) | System | Contractor | Cost ($K/m²) | Source |
|---|---|---|---|---|---|---|---|---|
| Australia | Central | 2,800 | ETFE/Steel | 180-200 | Modular | Laing O’Rourke | 4.2 | TfNSW |
| UK | Kings Cross | 3,200 | Glass/Steel | 160-180 | Traditional | Kier | 4.8 | Network Rail |
| Singapore | Woodlands | 2,400 | ETFE/Aluminum | 200-220 | Prefab | Samsung C&T | 4.5 | LTA |
| Germany | Berlin Hbf | 3,600 | Glass/Steel | 170-190 | Hybrid | Hochtief | 5.0 | DB |
| Japan | Tokyo | 4,200 | Glass/Steel | 190-210 | Modular | Taisei | 5.2 | JR East |
Installation Phase Analysis:
STRUCTURAL WORKS:
- Primary Structure:
- Column erection: 4-6 units/day
- Truss installation: 2-3 spans/day
- Purlin fixing: 15-20 units/day
- Bracing: 20-25 points/day
- Secondary Systems:
- Gutter systems: 30-40m/day
- Edge trim: 40-50m/day
- Flashings: 50-60m/day
- Drainage: 25-30m/day
COVERING SYSTEMS:
ETFE System:
- Installation Rates:
- Frame setup: 150-180m²/week
- Cushion install: 100-120m²/week
- Inflation system: 80-100m²/week
- Testing: 200-250m²/week
Glass System:
- Installation Rates:
- Frame setup: 120-150m²/week
- Glass install: 80-100m²/week
- Sealing: 150-180m²/week
- Testing: 180-200m²/week
Note 1: Production rates are indicative only.
Note 2: Rates vary based on:
- Design complexity
- Access conditions
- Interface requirements
- Weather impacts
- Installation method
- Safety requirements
Note 3: Installation calculation formula:
P = (BA × CF × HF × WF) – DC, where:
- BA = Base area
- CF = Complexity factor (1.2-1.6)
- HF = Height factor (1.1-1.4)
- WF = Weather factor (0.8-1.0)
- DC = Delay constant
MATERIAL SPECIFICATIONS:
ETFE System:
- Technical:
- Cushion thickness: 250-300 microns
- Light transmission: 95%
- U-value: 1.8-2.0 W/m²K
- Design life: 25-30 years
- Installation Requirements:
- Air supply system
- Monitoring system
- Fall protection
- Access systems
Glass System:
- Technical:
- Panel thickness: 12-16mm
- Light transmission: 80%
- U-value: 1.2-1.6 W/m²K
- Design life: 30-35 years
- Installation Requirements:
- Crane access
- Edge protection
- Temporary works
- Weather protection
Quality Control:
Testing Requirements:
- Structural:
- Deflection limits
- Water tightness
- Air pressure (ETFE)
- Movement joints
- Environmental:
- Thermal performance
- Light transmission
- Acoustic performance
- Wind resistance
Cost Breakdown:
Materials:
- Primary structure: 35-40%
- Covering system: 30-35%
- Secondary elements: 15-20%
- Services: 10-15%
Installation:
- Labor: 30-35%
- Equipment: 25-30%
- Access: 20-25%
- Testing: 10-15%
Note: All data subject to:
- Local standards
- Site conditions
- Access restrictions
- Station operations
- Testing requirements
- Environmental controls
- Maintenance access
- Safety protocols
Additional Considerations:
- Solar control
- Bird protection
- Cleaning access
- Drainage design
- Lightning protection
- Snow loading
- Future modifications
- Asset monitoring
Other production rates – Indicative only
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Our Partners
- FR2 Infrastructure – Constructability advise and project and planning controls
- Staging Diagrams – Staging diagrams for possession planning
Possession Planning – Current Possession Calendars
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