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The upgrading of the existing Barlow shed at St Pancras, whilst maintaining the essence of the structure to the satisfaction of English Heritage, involved significant innovations in both materials and methods. This paper describes the application of a very high strength, high steel fibre content cementitious material to resolve one particular design challenge. The work to accurately define and then solve the problem is presented including the analytical approach used, the testing of the novel material and the development of design parameters to feed back into the analytical model to verify the final design. David Gration , BEng CEng MIMechE Tony Jones , BEng PhD CEng FICE Andrew McNulty , MA MSc DIC CEng MICE