April 2008
Purlin Division
Rebuilding the 007 stage at Pinewood – Metsec purlins chosen for fast-track Project

When fire destroyed the famous 007 stage at the Pinewood Studios in Buckinghamshire in July 2006, the pressure was really on to rebuild it in time to meet the tight filming schedules for the feature film production of ‘Mamma Mia!’. Fast and accurate fabrication of Metsec light gauge galvanised steel purlins played a key part in getting everything completed on time.

Bourne Steel, the structural steel contractors for the rebuild project, were allowed only sixteen weeks from design to completion. Half of this demanding timescale was needed to carry out the off-site manufacturing programme including design detailing, fabrication, painting and delivery. Careful planning, fast production and reliable deliveries were therefore critical for Bourne Steel to be able to arrive on site with the first of over 1,450 tonnes of steel just eleven weeks after the fire.

The project also presented some unusual technical challenges. With trusses weighing in at 26.5 tonnes, complicated lifting operations were needed to work around the underwater tank in the centre of the site - the biggest in Europe, and originally built to hold three submarines in The Spy Who Loved Me.

Purlins and side rails were specified to connect the rafters and columns of the main steel structure, provide a security restraint, and support the composite steel cladding on the walls. For these, Bourne Steel called on Metsec’s Purlin Division - the UK's largest supplier of cold rolled steel zed purlin and C section profiles.

The light gauge galvanised steel purlins were produced at Metsec’s state-of-the-art facilities in the West Midlands, where technological innovation, quick change mills and automated CNC machinery ensure the highest degree of accuracy and fast production to meet urgent deadlines.

Completely fabricated and ready for use, a total of 170 tonnes of purlins and side rails were delivered direct to the Pinewood site, helping Bourne to work progressively on a few bays at a time, and successfully meet all the requirements of the demanding schedule.

The process was further assisted by Metsec’s specialised Metspec software, which enabled Bourne engineers to create the most accurate and economical purlin design. Starting from more than eighty different options of sizes and systems, Metspec is used by thousands of fabricators and consulting engineers to arrive quickly and easily at the optimum solution based on the relevant design criteria specific to the structure.

Alan Busbine, Associate Director at Bourne Steel, said: ”We have a long-standing relationship with Metsec as our preferred cold rolled steel supplier, and we deal with them regularly. Their people and service are excellent. They always do a good job, get it to us on time, and pull the stops out if we’ve got a problem.”

The new and much improved 007 stage is now the largest in Europe. Built within the same footprint as the one it replaced, its usable area of just over 59,000 square feet is over 30% larger than before, thanks to improved structural design. Enhancements include a drive-in ramp to the water tank and a new gantry system. Completed on time, the stage rebuilding project was followed swiftly by the creation of a new set – ready for the filming of Universal Studios’ ‘Mamma Mia!’ starring Pierce Brosnan, Meryl Streep and Colin Firth.

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