The scale of the repair work to rectify mistakes by original contractor Carillion has been revealed by the Royal Liverpool NHS Trust.
Replacement contractor Laing O’Rourke will start structural repairs this month after stripping out great swathes of the hospital to uncover the extent of the problem.
O’Rourke has been working with Arup to assess the original concrete frame with extensive structural repairs now needed across three floors.
Cladding and exterior finishes will also be stripped off the building this summer.
Arup director Jim Bell said: “Our structural review looked at the building as it is now and the building at its peak use, once the hospital is open and fully operational.
“The solutions to address these issues involve using tried and tested methods to strengthen existing beams, reduce loads that are causing structural issues and putting in place additional support.
“The works are highly complex and are necessary to ensure the building is finished to the high standards required.”
The structural interventions will require over 220 cubic metres of new concrete and 165 tons of new fabricated steelwork.
Andy Thomson, project director, Laing O’Rourke said: “Control measures are already in place to ensure there are no immediate risks to workers in the building.
“Fixing the structural issues is a complex programme of work, with the added challenge of protecting the existing hi-tech fixtures and fittings in the hospital.
Above ward prior to Laing O’Rourke strip out and below how it looks now after preparation for structural intervention
“This requires heating the building and maintaining water flow to prevent deterioration, which would lead to costly replacements if it was not diligently carried out.”
Work on the structural interventions will begin later this month.
To create access, to help transport materials like concrete and steelwork into the building, some of the cladding and exterior of the building will be removed over the summer.
Dr Peter Williams, chief executive of the Trust said: “Whilst work on these structural interventions is underway, the programme to complete the new Royal will be finalised.
“Once the programme is finalised and the costs are all accounted for we’ll confirm timescales and costs. We owe it to everyone to not raise expectations with speculation, until everything is signed, sealed and delivered.”