Luton Airport MSCP

Scope of Works

Berry systems were contracted to install our bespoke System 3 vehicle barrier system, complete will full-height mesh, across 4 floors of a new multi-story carpark (MSCP) at Luton Airport. Delivered within a revised 12-week schedule, the project was executed over eight continuous phases.

Approach

The original programme relied on prior trades completing their works before our installation began in each phase. However, delays during mobilisation required a shift in our approach. Working closely with the client, we adapted the plan dynamically, re-sequencing work and adjusting the scope to continue in areas that became available, this helped minimise overall delays and maintain momentum. Early identification of clashes and access constraints helped reduce disruption, but evolving site conditions revealed additional issues as the project progressed. The team carried out ongoing risk reassessments, adopting a collaborative, flexible mindset throughout the phases. 

Resources

Crew sizes flexed from 4 to 10 fitters and installers depending on the workload, ensuring efficient resource use. Despite initial delays in phased handovers, we coordinated with BAM to realign priorities and maintain progress. The project was completed on time and on budget.

Innovation and Design

The team encountered multiple clashes with splice plates shown as shown on the Issued For Construction (IFC) drawings, which conflicted with structural elements and installation paths. These design clashes could have led to significant delays without prompt resolution. To overcome these issues, bespoke brackets and custom-fabricated parallel flange channels (PFCs) were designed and manufactured. These bespoke elements accommodated the splice plate locations while maintaining structural integrity and compliance with specifications. This tailored engineering approach ensured the installation could proceed without compromising safety or performance. 

Collaboration and Client Engagement

Strong collaboration with BAM and supply chain partners, including 4M Floors and B&K, was critical in coordinating timelines and resolving interface issues. Open communication with the client allowed for agile decision-making, including adjustments to working areas based on evolving site access and priorities. Changes to the timeline, regular coordination meetings, and a proactive “can-do” approach helped mitigate delays and keep the project on track. 

Environment

To reduce the project’s environmental footprint, deliveries were consolidated to limit trips and lower emissions. Material quantities were carefully controlled to avoid over-ordering and unnecessary waste. 

Health & Safety

Accessing upper floors was a major challenge, especially without direct lift or forklift access. The team worked with the Compliance Department to implement safe methods of working at height, including the use of harnesses and detailed lifting plans. Due to airside restrictions, forklift use was prohibited so semi-electric pallet trucks were employed for the handling of materials. Hazards from debris left by other trades were mitigated through daily inspections, cleaning routines, and the use of a “Stop Work” policy where necessary. Regular inspections by Site Managers reinforced safe housekeeping practices, with tools and materials kept secure and work areas kept tidy at all times. 

Community Engagement

To ease local congestion, our teams adopted carpooling and parked off-site, around half a mile from the airport. The completed car park will relieve pressure on local parking facilities, supporting both residents and businesses. We also sourced materials and services locally, boosting the regional economy during the construction phase. 

Conclusion

This project demonstrated effective problem-solving, adaptability and teamwork in a complex, phased construction environment. Through bespoke design solutions, strong collaboration, and a clear focus on safety and environmental responsibility, Berry Systems delivered a critical infrastructure component on time and within budget while maintaining strong relationships with the client, stakeholders and local community.