Client: Arsenal Football Club
Main Contractor: Sir Robert McAlpine Ltd
Type of works: Ferco Seating manufactured a new seat to complement the new 60,000-seat stadium.
In 2005, Ferco Seating was awarded a £2.4m contract to manufacture a new seat to complement Arsenal's new 60,000-seat Emirates Stadium. Designs were finalised, moulds cut and tested, and off-tool samples approved in time for manufacture to begin in February 2006.
During construction, 40km of steel beams were used, along with 35,000m2 of vinyl, over 400 tonnes of polypropylene, 900m2 of faux leather, nearly 200 tonnes of stainless-steel straps, and almost 4 tonnes of bolts and anchors.
Special drilling jigs were designed by Ferco to prevent Hand Arm Vibration Syndrome (HAVS) during the drilling of 2.5km of holes in the high-strength (more than 60N) precast concrete elements.
The project was completed on time and within budget, much to the credit of the management style of Arsenal Football Club and Sir Robert McAlpine. Since the stadium opened, seat damage is running at less than one tenth of 1% of previous levels; testament to Ferco's seat design philosophy of minimising whole-life costs.