Film Studio
February 2022 - July 2023
60,000sq ft
About this project
Skyline DC Ltd was appointed to construct an art film studio on a Greenfield site, following the client’s decision to expand their existing studio business. Due to planning restrictions preventing residential development, the client opted for a high-specification studio space that would support large-scale film productions.
Challenges And Solutions
The project began with an extensive site strip and excavation, revealing significant variations in ground levels. To counteract this, we implemented a compact material layer to stabilise the site and form the necessary base layers for the concrete slab.
One of the key challenges was installing pad foundations, with some exceeding 12 cubic meters of concrete. These were interconnected with ground beams, forming a solid base for the steel frame structure. Precision was key, and our team worked closely with setting-out engineers to align all steels correctly.
To address drainage, we installed a multi-layered ‘aquacell’ system at the rear of the building, ensuring efficient water management for the large roof area. The steel frame erection involved more than 250 tonnes of steel, forming 13-meter-high stages with multi-storey office spaces at both the front and rear elevations.
Given the film studio’s unique requirements, advanced noise-canceling measures were necessary. Vibration dampers were installed on all steel connections, and acoustic insulation was a critical component throughout. Special Insul-Quilt soundproofing was imported from the United States to meet stringent acoustic standards.
Key Deliverables
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Groundworks & Foundations: Site clearance, excavation, and stabilisation of varying ground levels, along with the installation of deep pad foundations and interconnected concrete beams.
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Steel Frame & Structural Work: Erection of a 250-tonne steel frame, creating 13-meter-high studio stages, along with a double-storey office at the front elevation and a three-storey office at the rear, including vibration dampers to reduce noise transfer.
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Roof & Wall Cladding: Euroclad built-up roofing system for optimal insulation and energy efficiency, complemented by Kingspan XL Forte composite wall cladding designed to meet high U-values, with optimised cost savings achieved by using 1000mm panels on the front elevation.
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Specialist Soundproofing & Studio Features: Acoustic doors and sliding stage doors custom-built to minimise noise leakage, Insul-Quilt sound insulation installed on internal stage walls, and internal plywood perimeter walls designed to support advanced electrical trunking and fixing points.
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Mechanical, Electrical & Lighting: Advanced M&E installation to support high power demands, with custom acoustic hatches, a scaffold platform for high-level gantry work, and runway beams for filming industry cranes.
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Specialist Concrete Slab: 1,200m² jointless concrete slab, reinforced with metal fibre compound.
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External Works & Infrastructure: Secure external yard with sliding gates, highway connections with Hillingdon Council, and a 5-meter-deep foul water connection coordinated with the Water Network and local authorities.
Groundworks
Steel Frame
Construction Stage
Completion
