Technical services

Barton Square, Manchester

Challenge

In the centre of Barton Square in Manchester sits the impressive 250T steel and glass Main Dome constructed by VINCI Building as part of the redevelopment of the Intu Trafford Centre. A temporary tower structure was needed to resist vertical and horizontal reactions from the steel segments and ensure stability as this complex dome was constructed.

Solution

Technical Services provided engineering support by coordinating the temporary works and methodology with all parties. The team developed a phase-by-phase finite element model of the dome to understand the reactions imposed to the temporary tower and surrounding structure throughout the installation. This was followed by a peer review of the permanent works to validate the design for safe construction.

Benefits

Our construction support ensured that the method of installation was validated for both the permanent and temporary works, ensuring the safety of the structure, as well as providing a reduction in the programme project costs.

White Hart Lane Station Upgrade

Challenge

In 2019, Taylor Woodrow successfully completed the new White Hart Lane Station. The most challenging element of the new station was the installation of two underpasses through the existing Victorian brick viaduct which supports the existing platforms and track.

Solution

The Technical Services team worked with the permanent works consultant to offer an alternative tunnelling solution under the railway in place of a complex bridging structure which would have required extended disruption and risk within a railway environment. The process saw 118 underpins installed underneath existing brick piers to enable the surrounding ground to be lowered for the new station, 30 horizontal spiles installed to provide support during tunnelling operations, and two pre-cast boxes assembled on site then pulled under the railway during a 52 hour possession.

Benefits

The final solution dramatically decreased the duration to install the underpasses, eliminating the need for extended closures of the railway and the associated impact on the travelling public, along with the additional benefit of reduced project risk and programme.

Paterson Redevelopment Project

Challenge

At the Paterson Redevelopment project, completed by VINCI Building in 2023, a large basement excavation was required to be installed within a very constrained site located between a major road and the existing hospital building.

Solution

Working with the project team, Technical Services developed a leaner solution for the basement excavation and temporary propping. This was achieved by using the permanent works as part of the solution and collaborating with our suppliers and permanent works designers to finalise the detailed design. The team also provided a sequenced methodology to remove the props after the superstructure had commenced, allowing the project team to decouple this activity from the critical path.

Benefits

Through collaborative design, the reduction in temporary works required saved over £150,000 in hire costs, provided a 60% reduction in materials, and took weeks off the programme.

The team was also awarded the Ground Engineering ‘UK Project with a Geotechnical Value of up to £500k’ for the development of the temporary works design and methodology.

iPort Bridge Doncaster

Challenge

Designed with the local community in mind, the new £7m Porter’s Bridge will boost public transport, walking and cycling links to South Yorkshire’s major iPort employment site. The new bridge was located in a constrained position, with poor ground conditions along with a steep embankment leading down to the River Torne.

Solution

Working collaboratively with the project team, Technical Services developed a detailed earthworks methodology to level the existing terrain, install the working platform and a provide a temporary retaining wall to enable the construction of the permanent piles and abutment. The team utilised lime stabilisation to improve the upper soft clay and chose a temporary king post wall design, to utilise the strength of the deeper chalk subgrade.

Benefits

A good collaborative relationship between design, construction and client teams allowed Taylor Woodrow to complete the works to budget and programme. Sequenced earthworks and the use of lime stabilisation reduced C02 emissions and heavy plant movements within the local village, with the added benefit of a reduction to the programme.

The project received nomination at the 2023 Highways Awards.

Spalding Relief Road

Challenge

The Spalding Western Relief Road will provide a new route around the western side of the town, reducing journey times and traffic congestion in the town centre and as part of the new road, a new three span bridge is required constructed over the existing Network Rail lines. Typical to the local area, the site has extremely challenging ground conditions with a combination of high-water tables, soft clays, and peaty soil; providing added complexity to temporary works on the project.

Solution

Numerous excavations were required in order to construct the piers and abutments for the new bridge. The variable water table increased the risk of both collapse and heave within the proposed cofferdam structures. Technical Services worked collaboratively with the site teams to design the cofferdams with the innovative use of supporting base slabs utilising integrated sump pits which could be sealed or opened to allow water management after installation.

The central section of the new bridge required 130t of steelwork to be lifted over Network Rail assets. Technical Services worked closely with site teams and sub-contractors to aid in heavy lift planning and precast element placement.

Benefits

All excavations were completed without incidence and without the requirement for costly and risky dewatering operations.

All works were coordinated and assured with Network Rail to ensure that risk to the operational railway was managed, and the project programme could be maintained.

Old Oak Common Station - WP15 Bridge

Challenge

At the HS2 Old Oak Common Station, a proposed permanent bridge abutment clashed with existing utility mains. Programme constraints on the utility diversions would inhibit the construction of the bridge with major implications to the wider project and result in railway possession milestones being missed.

Solution

Technical Services completed optioneering for both a temporary or permanent extension to the bridge to delink the bridge deck construction from the utility diversions. We worked with precast beam manufacturers to assure the viability of the solution which included hybrid reinforced concrete and prestressed bridge beams.

The central section of the new bridge required 130t of steelwork to be lifted over Network Rail assets. Technical Services worked closely with site teams and sub-contractors to aid in heavy lift planning and precast element placement.

Benefits

The feasibility study provided the project team with an option to return to the permanent bridge designer to update the permanent solution in line with the findings. The permanent designer did not have the resources available to complete this study within a short time frame required by the project, and so Technical Services team was able to assist in exploring the options without affecting the main permanent work design programme.

HS2 N1 & N2 Sublot Delta

Challenge

A working platform design was required for the construction of two Water Orton viaducts, each stretching for over 2 kilometres and located between the M42/M6 toll motorways, the A446, the Whitacre and DB2 Derby railway lines, the River Tame and the Minworth Conduit; the interfaces with which all need to be managed. The working platform was to enable the install of piled foundations, working room for the pier construction works and the lifting arrangements for the precast viaduct segments and had to allow for confined access, utility crossings, varied ground conditions and topography, as well as considering multiple phases to suit construction sequences.

Solution

Phased and sequenced designs were produced with platform levels tailored to the location and required working sequence in order to minimise cut and fill. Stabilising geogrids were used to minimise the required platform thickness where appropriate. Swept path analysis for the required plant were also run for critical areas where required topography or working room was tight. Technical submissions were submitted to Network Rail and National Highways to assure the design with key stakeholders.

Benefits

Clear design drawings and models provided to the site team tailored to the programme and construction methodologies to allow the designed sequence to be efficiently implemented on site. Interfaces were closely reviewed, and technical submissions developed with our key stakeholders to manage the risk to the adjacent roads, railways, and rivers. The volume of cut and fill material was minimised, reducing material use and associated CO2 emissions.

HS2 N1 & N2 Curzon Street Viaduct

Challenge

BBV Joint Venture required the design of a foundation for the temporary tower enabling the launching of Curzon Street 2 Viaduct. Due to program constraints the design was split in 2 phases: piling design, to enable construction at the same time as the permanent work piles, and pile cap design, to proceed once steel tower design was completed.

After the piles had been completed, the permanent works designer informed of a significant increase in the transversal loads during the launching, that could not be accommodated by the existing design.

Solution

The increased loading indicated from the tower meant that both the bending and shear capacity of the single piles supporting the props was exceeded to more than twice the capacity, however the piles supporting the main tower were satisfactory.

The solution was to adapt the pile cap design tying together all six of the already constructed piles, distributing the horizontal shear among the piles and, also, providing fixity to the pile head, reducing the maximum bending moments.

Benefits

AOur knowledge of different design disciplines and a holistic understanding of the design and construction requirements allowed us to identify potential solutions and optimisations, which ultimately allowed us to provide a workable solution to the project team.

Technical Services were able to adjust the original design approach to accommodate the changes and prevent additional mobilisation for piling works that would have impacted cost and program.