Project Overview
Armadillo Engineering manufactured a comprehensive package of bespoke stainless steel roof support frames and aluminium panel systems for the Tottenham Hotspur Stadium's Sky Bridge, a striking suspended structure positioned high within the stadium.
The project called for approximately 135 metres of custom aluminium panels, each measuring up to 6 metres long by 2 metres high. All panels were bespoke, with no repetition. Every component featured its own unique geometry, dimensions, and interface details.
Unlike conventional fabrication projects, there were no standard right angles, and very little repetition throughout the entire fabrication.
The Challenge
The complexity came in three forms: the geometry itself, the volume of unique components, and the logistics.
Every stainless steel frame was manufactured to its own specific dimensions. The aluminium panels incorporated complex architectural lines and flowing angles. The architect's vision didn't allow for shortcuts: accuracy had to be exceptional across every single piece.
But the real constraint was installation. The bridge was built on a restrict night-time working only.
The stadium couldn't have fabrication activity or extended on-site work during the day. That meant every component had to arrive on site correctly identified, ready to install, and in the sequence required for that night's lifting operation. Selecting the wrong component, or having to hunt through a container to find the right one, would blow the schedule immediately.
Scope of Work
We delivered:
- Bespoke stainless steel roof support frames, each to its own specification
- Approximately 135 metres of custom aluminium panel systems
- Panels up to 6m × 2m, with no repeated designs
- Complex geometry interpretation and manufacturing to the architect's tolerances
- A robust production and identification system that tracked every component
That identification system was the backbone of the project. Rather than simple sequential numbering, we developed a logical labelling strategy that corresponded directly with the installation sequence and the specific location of each component within the structure.
Every stainless steel frame, aluminium panel, bracket, and associated component was individually labelled and tracked throughout manufacture and delivery.
Scale & Delivery
Hundreds of unique components. Each one was manufactured, inspected, labelled, recorded, and packaged in a manner that supported the planned installation sequence.
This wasn't just fabrication; it was precision manufacturing paired with logistical discipline.
All components were delivered on schedule and to specification.
The Outcome
The identification system proved critical to on-site efficiency. Installation teams could quickly locate and select exactly the right component for each stage of the night-time build, reducing delays, minimising unnecessary handling, and keeping the installation running to schedule.
The completed Sky Bridge now stands as one of the stadium's most visually distinctive features.
A demonstration of our capability to deliver large-scale architectural metalwork where accuracy, traceability, and logistical planning are just as important as fabrication expertise.
This is what Armadillo Engineering does: take on complex, non-repetitive metalwork where precision and planning have to be absolute, and deliver exactly what was promised.
Whatever the challenge, we'll find a way to build it. Tell us about your project.
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