Case Study:

Tottenham Court Road Underground Station

Main Contractor

Laing O'rourke

Project Type

New Underground Station

Project Value

Crossrail - Tottenham Court Road Station

The Project

As part of the £17.6 billion Crossrail project, Tottenham Court Road underground station was given a major transformation. Located in the heart of London’s West End, Tottenham Court Road was expanded with a new underground station and ticket hall and a second integrated ticket hall.


Used by more than 200,000 people every day, Tottenham Court Road Station is one of the busiest Underground Stations in London. 


First opened in 1900 and located in the West End, Tottenham Court Road has proved to be one of the most important stations in central London, and is sometimes referred to as the ‘Gateway to the West End’.


Recently, the station underwent a major transformation as part of the multi-billion pound Crossrail project. 


Crossrail is currently Europe’s largest infrastructure project. The new railway, which is the focus of the project, will be fully integrated with London’s existing transport network and will be operated by Transport for London.


Once the entire project is completed, it is estimated that 200 million passengers each year will benefit from Crossrail, bringing roughly £42bn to the UK economy. 


The project will serve 41 stations including 10 new stations at Paddington, Bond Street, Farringdon, Liverpool Street, Whitechapel, Canary Wharf, Custom House, Woolwich, Abbey Wood and of course, Tottenham Court Road. 


The Tottenham Court Road project delivered a new underground station and ticket hall at Dean Street in Soho and a second integrated ticket hall below St Giles Circus on Oxford Street. 


At SuperFOIL, we were honoured to be chosen to be a part of this historic development.

The Problem

Due to the huge reconstruction of the station, it was in need of a modern, high performance and non-combustible insulation solution which wouldn’t have a visible impact on the overall design of the station. A combination of attributes that traditional insulation products struggle to deliver.

How We Helped

Lead developers of the reconstruction approached SuperFOIL to provide an insulation solution for the entire Tottenham Court Road project. SuperFOIL’s experts concluded that our non-combustible SFNC would be the most suitable product as the design required the use of non-combustible materials.


SuperFOIL SFNC was the obvious choice over traditional glass or rock wool insulation which wouldn’t meet the required insulation performance within strict space requirements. Equally, rigid foam board wasn’t appropriate for this type of project due to its fire performance. SFNC multi-foil insulation is cost-effective, high performance, easily applied and it has a slim profile, measuring just 20mm thick. SFNC met the high thermal performance required without taking up much-needed space.


SuperFOIL SFNC is a high performance Euro Class A1 Non-Combustible multifoil insulation and is the only non-combustible multifoil insulation product on the market.


The improved airtightness provided by SuperFOIL Superior Tape with SFNC’s thermal performance and reflective foil surfaces, combine to create the high-performance insulation system needed for this project. SuperFOIL Superior Tape is a high performance fully reinforced foil tape recommended for sealing all seams, joints and edges of SuperFOIL multifoil insulation.


After providing main contractors Laing O’Rourke with SuperFOIL SFNC, the application of the insulation was a complete success and the station reopened in 2017, allowing millions of people to visit the West End of London every year.


Will Bown, Managing Director of SuperFOIL, said:


“We’re delighted with how this project turned out, providing insulation for Tottenham Road Court is one of our biggest accomplishments to date.


“They’ve done a great job of installing our SuperFOIL SFNC Insulation and the whole station looks fantastic. SFNC is completely non-combustible so visitors and commuters can be assured that developers have chosen the best and safest products to complete this project.”

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Here are just a few of the comments we've received...

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Loft Conversion

Actually, I bought Superfoil for my small extension and I must say easy to install and it works, room is comfortable better than Kingspan. Now looking at installing an underfloor in my daughter's house. Thanks!

Duncan Walker

Conservatory Conversion

I'm really grateful for all the info you've provided, many thanks. To be honest I didn't think your stuff is as good as it clearly is, and we'll definitely be using it in the future. Can I ask a favour and ask you to calculate two more please?

Carl Bell

Self Build

In the past, I used SF19 for thermal insulation of the roof. I have the best experience. I'm thinking about insulating the house outside wall. As I want to be clear, I will definitely call. Many satisfied customers wish.

Jiri Milfait


We’re delighted with the thermal improvements after fitting Superfoil SF40. The system was clearly and helpfully specified, simple to install and immediately felt warmer, despite this also being the Winter of Beast from the East. It suits our 200 year old house, now heated with a modern, green air source heat pump.

Tim Clements

Senior Building Control Surveyor

Many thanks for all your assistance with this matter, you have been very helpful. The information you have provided has been very useful to one of our customers and I am now more familiar with this type of double fit of SuperFOIL as a suitable method of achieving compliance with The Building Regulations.

Donna Worrell

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