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Overview
Hay’s Galleria is one of London’s most recognisable historic commercial buildings. Located on the south bank of the River Thames near Tower Bridge and within sight of The Shard, the former wharf complex has been transformed over the years into a vibrant mixed-use destination that includes offices, retail spaces, cafés, and restaurants.
Originally constructed in the 17th century, the building has endured centuries of use and survived extensive bombing during the Second World War. As a Grade II listed structure, any refurbishment or maintenance work must carefully preserve its architectural character while ensuring the building continues to function effectively in a modern commercial environment.
As part of a planned maintenance programme, the west elevation of Hay’s Galleria required complete reglazing. The existing glazing had reached the end of its service life and needed to be replaced in order to extend the longevity of the building envelope and improve environmental performance.
Structura was appointed to deliver the reglazing works across the west elevation, replacing more than 2,000 individual glass units. The project required extensive on-site surveying, bespoke glass manufacturing, and careful installation within a busy and operational public environment. The work demonstrates how specialist façade engineering and glazing expertise can restore historic structures while improving their performance and usability for modern occupants.
Details
Client:
Savills
Location:
London Bridge
Architect:
Pascall + Watson
Principle Contractor:
Structura UK Ltd
Project Metrics
Key performance and project metrics include:
Building Type: Grade II listed historic commercial building
Scope of Work: Complete reglazing of the west elevation
Glass Units Installed: Over 2,000 bespoke glass panels
Glass Panels Per Window: Nine panes per window assembly
Installation Team: 12 specialist installers
Project Duration: Seven months
Additional Works: Frame respraying and ironmongery replacement
The Challenge
Reglazing a historic Grade II listed building presents a unique set of technical, logistical, and conservation challenges. Unlike modern buildings where glazing systems can be manufactured using consistent dimensions, heritage structures often contain irregular openings and delicate materials that require a bespoke approach. For Hay’s Galleria, the project team had to overcome several key challenges.
Preserving a Historic Listed Structure
As a protected Grade II listed building, Hay’s Galleria required all refurbishment works to maintain the architectural integrity of the structure. Historic buildings typically contain original window frames, structural elements, and materials that cannot be replaced without careful planning and approval. Any glazing replacement needed to replicate the existing visual appearance while delivering improved performance. In addition to the glazing itself, many architectural details such as ironmongery and frame finishes had to be preserved or replaced with materials that matched the original specification.
Non-Standard Window Dimensions
One of the most technically demanding aspects of the project was the fact that very few of the windows were identical in size. The west elevation contained a large number of openings with subtle dimensional differences, meaning that a standardised glazing approach was not possible. Each window required bespoke glass panels manufactured specifically for its opening. To achieve this level of precision, every glass panel had to be templated individually on site. Templates were created from inside each window opening to ensure the new glazing units would fit accurately within the existing frames. In total, this process resulted in the production of more than 2,000 bespoke glass panels, each tailored to the unique geometry of its respective aperture.
Complex Multi-Pane Window Assemblies
Each window within the west elevation contained multiple pieces of glass. A total of nine individual glass panes were required per window, increasing the complexity of both the manufacturing and installation processes. Because the glass shapes varied between openings, each pane had to be produced and delivered with extreme accuracy. Even minor dimensional discrepancies could result in installation delays or the need for replacement units. The careful coordination between surveying, manufacturing, and delivery was therefore essential to ensure the glazing could be installed efficiently once it arrived on site.
Working Within a Busy Public Environment
Hay’s Galleria is not only an office building but also a popular public destination featuring cafés, restaurants, and retail spaces. The glazing works therefore had to be carried out while the surrounding businesses remained operational. Installation activities took place directly above pedestrian areas and commercial spaces, requiring careful site management to maintain public safety and minimise disruption. Protective scaffolding systems were installed to shield the areas below while allowing workers to safely access the building façade. Managing pedestrian flow through the area was also a critical aspect of the project’s planning and execution.
Delivering the Project During the Pandemic
The project was undertaken during the COVID-19 pandemic, adding an additional layer of complexity to site operations. Health and safety protocols required careful coordination of working teams to ensure compliance with public health guidelines. Workers were organised into dedicated teams operating within controlled working groups, or “bubbles,” to minimise risk while maintaining productivity on site. Despite these challenges, the project continued to progress according to the planned programme.
Structura’s Solution
Structura approached the Hay’s Galleria project with a focus on precision surveying, bespoke glass manufacturing, and careful on-site coordination. The solution combined traditional craftsmanship with modern project management techniques to ensure the historic structure could be upgraded while preserving its architectural identity.
Bespoke On-Site Templating
The first step in the project involved detailed measurement of each individual window opening. Because the apertures varied in size and shape, templating was carried out directly on site to ensure absolute accuracy. Templates were drafted from inside each window opening, capturing the precise dimensions and geometry required for each pane of glass. This process was repeated for every glazing unit across the west elevation, resulting in templates for more than 2,000 bespoke glass panels. The templating phase was critical to the success of the project because it ensured that each glass panel would fit perfectly within the existing historic frames.
Custom Glass Fabrication
Once the templates were completed, the glass panels were manufactured to match the exact specifications required for each window. With nine glass panes per window, the total volume of bespoke glass required for the project was substantial. Manufacturing such a large number of individually sized glass units required precise coordination between the surveying team and the glass fabrication specialists. Careful labelling and tracking systems were implemented to ensure each pane could be delivered to site and installed in its correct location.
Careful Delivery & Handling
Because the glass panels were bespoke and many featured complex shapes, careful handling and transportation were essential. Each delivery to the site had to be planned meticulously to prevent damage during transport and ensure that the installation team had the correct panels available at the appropriate stage of the project. The sequencing of deliveries also helped minimise storage requirements on site while maintaining efficient installation progress.
Refurbishment of Internal Frames
As part of the refurbishment works, the existing internal window frames were resprayed to modernise their appearance. The frames, which had previously been finished in an ageing cream colour, were resprayed to a clean and contemporary white finish. This change helped refresh the interior appearance of the building while maintaining compatibility with the historic architectural features. The spraying works formed part of a broader CAT B office fit-out, improving the working environment for tenants within the building.
Conservation-Matched Ironmongery Replacement
Another important element of the refurbishment was the replacement of the existing ironmongery associated with the window systems. Because of the building’s listed status, the new ironmongery had to closely match the original components to preserve the historic character of the façade. This required sourcing and installing replacement fittings that replicated the existing design while meeting modern durability standards.
Coordinated Installation Programme
A dedicated core team of 12 specialists carried out the glazing works over a period of seven months. The team carefully coordinated installation activities to ensure safety, efficiency, and compliance with both conservation requirements and pandemic safety guidelines. Protective scaffolding systems and safety barriers were installed throughout the project to safeguard the public areas beneath the façade. The installation sequence allowed the team to progressively replace the glazing across the elevation while maintaining a controlled and safe working environment.
Project Results
The Hay’s Galleria reglazing project successfully restored and upgraded one of London’s most recognisable historic commercial buildings. By combining careful craftsmanship with modern glazing techniques, Structura was able to improve the building’s performance while preserving its historic character.
Improved Energy Efficiency
The new glazing systems provide significantly improved thermal performance compared to the ageing glass previously installed. Better insulation helps maintain more consistent internal temperatures, reducing energy consumption and contributing to a more sustainable building envelope. For office tenants, this improvement translates into a more comfortable and efficient working environment.
Enhanced Acoustic Performance
Located in a busy area near Tower Bridge and The Shard, Hay’s Galleria is exposed to a high level of urban noise. The replacement glazing provides improved sound insulation, helping reduce external noise levels within the office spaces. This contributes to a quieter and more productive working environment for building occupants.
Preservation of Architectural Character
Despite the large scale of the glazing replacement programme, the visual appearance of the building was carefully maintained. The bespoke glass panels and conservation-matched ironmongery ensured that the historic façade retained its distinctive architectural character. This balance between preservation and performance is essential when working with heritage structures.
Efficient Delivery in Challenging Conditions
Completing the project during the COVID-19 pandemic demonstrated the effectiveness of careful planning and disciplined site management. By organising workers into dedicated teams and implementing strict safety protocols, the project team was able to maintain steady progress while protecting both workers and the public. The glazing works were successfully completed within the planned seven-month installation period, despite the challenges of operating within a busy public environment and during a global pandemic.