Engineering Excellence Above London: Delivering a Class A Fire-Rated Rooftop at Harrods

Transforming a former helideck atop one of the world’s most iconic retail destinations into a luxury rooftop event space is not a typical construction challenge. It requires technical precision, uncompromising safety standards, and a deep understanding of how performance systems integrate with architectural ambition. The redevelopment of Harrods’ former helideck into a high-end rooftop venue is a perfect example of how engineering excellence and collaborative delivery can achieve outstanding results in one of the UK’s most demanding environments.

At the heart of the project was a clear brief: the rooftop deck needed to be fully compliant with Class A fire performance requirements, capable of supporting high footfall, and visually aligned with both the historic Harrods building and a newly constructed internal pavilion. With panoramic views across London and a fixed deadline ahead of Harrods’ first rooftop event in late May 2025, there was no margin for compromise.

A Collaborative Approach to a Complex Brief

Harrods, a globally recognised name synonymous with quality and luxury, appointed Kendall Kingscott Ltd to lead the architectural design. TC&D Construction was brought on board as specialist contractor, responsible for managing the on-site installation and overcoming the significant technical challenges presented by the roof structure.

To meet the stringent fire, performance and aesthetic requirements, Fire Deck supplied Exadeck porcelain decking boards, while Wallbarn provided the Class A fire-rated substructure solution. From the earliest stages, Fire Deck and Wallbarn worked closely with TC&D Construction, offering technical guidance, layout support, site visits and responsive delivery coordination to ensure the installation ran smoothly and stayed on programme.

This level of collaboration was critical. Rooftop schemes of this nature require more than off-the-shelf solutions; they demand systems that can be adapted intelligently to the realities of the structure below.

Overcoming Structural and Installation Challenges

One of the most significant challenges was managing varying floor heights across the rooftop. In some areas, differences of up to 400mm needed to be accommodated while maintaining seamless transitions between internal and external spaces. In addition, the roof featured multiple complex access points and ramped sections, all of which had to meet accessibility requirements without disrupting the clean, refined appearance expected of a Harrods development.

Wallbarn’s I-Plus aluminium rail system proved instrumental in overcoming these challenges. Designed for strength, accuracy and flexibility, the system allowed installers to construct a stable and perfectly level framework, even across uneven substrates and complex layouts. The use of MetalPad Ex pedestals provided precise height adjustment while maintaining full Class A fire compliance, a critical requirement for this project.

For the ramped sections, rails were cut to exact angles and cross-fixed to form a rigid substructure capable of supporting both the gradient and the anticipated foot traffic. This level of detailing required skill, experience and confidence in the performance of the system being installed.

Precision as a Design Requirement

The design team selected a stacked bond layout for the Exadeck porcelain boards. While visually striking, this configuration is significantly more demanding than more forgiving patterns. Even the smallest misalignment would have been immediately visible, particularly in such an open, expansive setting.

This risk was mitigated through the inherent precision of the Exadeck boards themselves. Each board undergoes a double-rectification process during manufacture, ensuring both the sides and the underside planes are perfectly straight. This eliminates rocking, movement and dimensional inconsistency, all of which can undermine alignment on site.

When combined with Wallbarn’s 60mm wide aluminium joists, which offer exceptional flatness and tight tolerances, the result was a system that allowed installers to achieve flawless lines across the entire deck. Compared with other systems available on the UK market, the consistency of components significantly simplified installation while raising the overall quality of the finish.

Secure Fixing for Long-Term Performance

Once the substructure was in place, the Exadeck boards were installed using the Class A W Clip fixing system. This concealed fixing method not only contributes to the clean, uninterrupted appearance of the finished deck, but also ensures each board is held securely in place.

Strength and durability were central considerations throughout the design and installation process. The rooftop space is intended for regular use, hosting events and accommodating high volumes of foot traffic. The combined system was engineered to withstand these demands while maintaining stability, safety and visual appeal over time.

Balancing Aesthetics with Durability

While technical performance was paramount, the visual impact of the space was equally important. Exadeck’s wood-effect porcelain finish delivered the warmth and natural character desired by the client, without the maintenance challenges associated with real timber. With 17 different patterns across the boards, the surface avoids repetition and enhances the authentic appearance of wood grain and knot detailing.

The material’s superior scratch and stain resistance makes it particularly well suited to high-traffic environments, ensuring the deck retains its appearance even under intensive use. This balance of beauty and resilience aligns perfectly with the expectations placed on an ultra-luxury destination like Harrods.

A Flawless Result for an Iconic Setting

The completed rooftop event space is resilient to weather, silent even during rainfall, and delivers the flawless finish expected of a project of this stature. Every detail, from fire performance to alignment accuracy, has been carefully considered and executed.

This project demonstrates how advanced decking systems, when combined with expert design and collaborative delivery, can unlock complex rooftop spaces safely and successfully. For Wallbarn, it is a showcase of how Class A fire-rated substructures can support not only compliance, but creativity, precision and architectural excellence at the very highest level.

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