Phased Steel Structure Retrofit for City Centre Apartment Redevelopment

Urban Apartment Redevelopment – Internal Structural Steel Framework Hayes Mechanical & Engineering was appointed to design, fabricate, and install a structural steel framework for the redevelopment of a multi-storey apartment building in a tightly constrained, densely built urban environment.

The building had suffered decades of deterioration and could not be demolished due to planning and boundary restrictions. The project strategy centred around a phased internal steel insertion, delivered in six sequenced stages. Each phase had to function independently, as works in one area directly impacted the structural stability of surrounding zones.

This demanded precision, adaptability, and constant coordination across disciplines. Internal walls were misaligned, cracked, and inconsistent in thickness and elevation. Standard framing methods were unsuitable, so bespoke layouts were developed for each bay, based on in-situ measurements.

Walls were selectively chased or partially broken out, and baseplates sunk two feet below floor level, fixed in reinforced concrete footings tied with rebar cages. Due to restricted access and limited lifting options, all steel components were prefabricated offsite to tight tolerances and delivered just-in-time.

Beams, columns, and brackets were cut to size, fire-rated, coated, and installed to millimetre accuracy—minimising handling and avoiding site congestion. Unexpected structural anomalies, such as concealed pipe runs, cavity voids, and misalignments, required continual redesign during construction.

External constraints included a lack of laydown space and live traffic management, with major lifts planned during low-activity periods. Internally, steelwork was integrated with new concrete slabs and retained masonry, requiring high-precision collaboration with blockwork and follow-on trades. Each phase was sequenced with floor, insulation, and waterproofing works.

The result is a hidden yet robust structural frame, embedded with surgical precision—delivering lasting reinforcement within an unpredictable shell.