Heathrow Terminal 5

The vast programme of works commissioned at Heathrow Terminal 5 constituted one of the largest and highest profile construction projects in Europe. The programme comprised five main projects, 147 sub-projects and more than 3,000 packages of work. Each project was interdependent and had to run concurrently; all had to be built, tested and operational in order for T5 to open. The challenge was in the sheer scale of the terminal building: the main hall is 40 metres high, 396 long and 176 wide, while T5A has 11 floors of which six are below ground and five are above. Added to the scale was the issue of how best to install an 87 metre high control tower in the centre of the world's busiest international airport.

Mace was appointed to provide consultancy, logistics and main contracting on the programme covering the design, build and delivery of component projects. One of the biggest challenges was the building of the control tower without cranes. The viewing tower cab was built off site and moved into place overnight, without interrupting air traffic, and raised to full height over a period of four months. Mace also delivered a very successful social inclusion programme, providing training and jobs for those with barriers to employment. The T5 programme called for a number of engineering firsts and enabled Mace to demonstrate best practice, innovative construction methods and continuous improvement.  

Mace won a Structural Steel Design Award 2008 for its work on the terminal building. 

Timelapse of roof lift: