Big Foot Provides a Big Support for Prestigious Infrastructure Project


Install DateSummer 2016
SupportedAHUs Ductwork
Big FootCustomer HD Frames, HD Beams & HD Cubes

Big Foot Systems has supplied HD Cubes, HD Beams, Bespoke Frames and Custom HD Frames to support large amounts of ventilation equipment being used during the construction of a prestigious infrastructure project. Big Foot’s products support ventilation equipment and ductwork which was needed during the construction of a new railway line.



Big Foot became involved in the project once the tunnels for the line had been bored. The fit out and track laying was taking place but there was no ventilation. Very large air handling units (AHUs) and hundreds of metres of ducting all required support in order to provide fresh air to the tunnels and underground stations during construction before the permanent infrastructure was installed.

The chosen solution was to fit enormous AHUs at either side of the central section, requiring very specific supports. Custom Heavy Duty frames supported two 100m3/s AHUs that were installed in the old rail tunnels with extremely limited clearance both underneath and above the units. Hundreds of metres of 3x3 ductwork were supported by Custom Heavy Duty to connect the AHUs to the outside. 

The biggest challenge was supporting a 60,000kg, 25x8x5m 200m3/s AHU sited outside, with a 6x6m duct rising 10m to the building entry point. Dozens of Big Foot’s HD Cubes and Beams made up the ground level support, with a custom steel structure holding the high level ductwork, for which a full FEA analysis was carried out to ensure stability.

“This complex and unique project involved the largest and heaviest units Big Foot has ever supported and was extremely technically challenging. It required large amounts of support in a tight space, much of it custom to the project” explains Ashley ten Wolde, UK Project Team Manager, Big Foot Systems. “The work carried out by Big Foot Technical, such as the FEA analysis, was crucial to the success of the project and our Project Engineer’s hard work has resulted in a very satisfied client and seamless project delivery.”


HD Custom Frames are project specific non-penetrative support frames for large, heavy, irregular shaped or unevenly loaded plant. With the aid of technical surveyors, a highly skilled engineering team and use of engineering tools such as ANSYS (FEA/CFD) etc. Big Foot Systems can design and manufacture complete one-off solutions. Solutions include frames similar to a standard LD product but utilising larger and longer sectional bars; a custom arrangement of HD Cubes or HD Beams; or, for more complex applications, a frame can be designed and fabricated specifically for the project requirements.

HD Beam is a non-penetrative support frame for chillers, AHUs, packaged plant, generators, pipes and steels. It is a robust but flexible solution where space may be limited, or there is a requirement to position directly over existing structural roof beams, and weight is evenly distributed across the specified quantity of HD Beams. It is also height adjustable to maintain a level system on roof falls up to 5 degrees.

The adjustable HD Cube provides a complete, efficient and robust solution for supporting heavier services and is an alternative to heavy complex frameworks. Offering fast assembly, available in multiple configurations, HD Cube offers excellent load distribution making it ideal for the support of large packaged plant rooms, chillers and large air handling units.

Offering specifiers a comprehensive range of freestanding systems, Big Foot’s products are designed and manufactured by the company for a wide variety of applications, including HVAC, solar units and safe access equipment. The product portfolio provides complete, simple, safe and secure non-penetrative, prefabricated roof support systems negating a need for time consuming and costly penetrations through the roof.

Big Foot Systems’ products and systems are quick and easy to install ensuring project cost and time clarity, thus reducing the need for complex, time-consuming and expensive detailing. Offering improved roof aesthetics, Big Foot Systems provides engineered solutions that are innovative in design, robust and repeatable. Big Foot combines market leading products and services, which include system design and on-site support. Available to install in all weathers utilising familiar componentry, all systems are designed with safety, security and simplicity in mind. Finally Big Foot Systems offers short manufacture and delivery lead times to help a project meet its schedule and stay within budget.

For further information on all products and services offered by Big Foot Systems email: enquiry@bigfootsupport.com or telephone 01323 844355.