First of 1,000 giant HS2 bridge segments roll-off factory line – video

Aaron Morby 2 years ago
Share

HS2 contractor Align has rolled out the first enormous pre-cast bridge segment for Colne Valley viaduct, set to be the UK longest railway bridge in the UK.

The huge deck segments each weighing up to 140 tonnes are being made at a purpose-built 100m long factory building that is bigger in internal volume than the Royal Albert Hall.

The construction team, which includes VSL, Danny Sullivan, Sendin and Tarmac, will cast and install a total of 1,000 concrete segments, each the size of a double-decker bus.

At the peak of construction, around 12 segments will be cast every week using a ‘match-casting’ technique.

This sees each segment poured against the previous one as a cast to ensure the whole arch fits perfectly when reassembled on site.

Every segment will be a slightly different shape depending on where it fits into the viaduct.

Vast temporary pre-cast segment factory ensures quality, safety and efficiency in production, and avoid bringing segments in by road.

HS2 Project Client, David Emms said: “We’re already making strong progress on the Colne Valley Viaduct – sinking the foundations, building the first piers, and now starting production at the new modular viaduct factory.

“Once complete, this iconic structure will carry trains at up to 200mph – improving connections across the UK, freeing up rail capacity and offering passengers low carbon travel options.

“It’s great to see how much progress has been made and I look forward to seeing work on assembling the deck structure later this year.”

Daniel Altier, Align Project Director “Seeing the first deck segments being cast in the factory marks a significant milestone for the project. The design of the viaduct is such that each segment will be unique, delivering a structure which I have no doubt will be one of the most striking elements of HS2 once complete.”

The design of the Colne Valley Viaduct was inspired by the flight of a stone skipping across the water, with a series of elegant spans, some up to 80m long, carrying the railway around 10m above the surface of the lakes, River Colne and Grand Union Canal.

Work has also begun on the 56 giant piers that will support the viaduct, working from north to south.

Weighing in at around 370 tonnes, the first 6m tall reinforced concrete pier was cast on site by a team of engineers who used a specially-designed formwork to create the shape of the structure. This was then removed after 4 days to reveal the final product.

Each pier is designed to support the full weight of the deck above and rests on a set of concrete piles going up to 55m into the ground. This foundation work began earlier this year and will require the construction of 292 piles and 56 pile caps across the whole length of the viaduct.

Once complete, the team will then use a specialised ‘launching girder’ resting on top of the piers to lift the deck segments into position.

Latest news

Geoffrey Osborne files administration notice

Contractor in talks to save parts of the business
1 day ago

RG Group signs £121m Newcastle rental homes job

Developer Olympian Homes advances 519 flats plan at Pottery Lane site
21 hours ago

Winners named for £260m Manchester Uni framework

B&K, Henry Bros, Graham, Robertson and Vinci among new line-up
1 day ago

Shed specialist Benniman rides out market lull

Worcestershire warehouse builder says industrial and logistics work is picking up again
24 hours ago

Another contractor cleared after high profile immigration raid

Adana Construction employees were working legally on site swooped on by Home Office
24 hours ago

McAleer & Rushe wants to meet new London suppliers

Contractor holding Meet the Buyer event in London: Register now
1 day ago

McAlpine signs £500m Broadgate dual towers deal

Work to start on iconic 36-storey and 21-storey towers
2 days ago

Worker rescued from collapsed four metre deep trench

Fire crews take six hours to save trapped builder near Blackwall Tunnel
2 days ago

Gove puts another major building scheme on hold

Secretary of State starts another planning fight after M&S defeat
3 days ago

Greenwich University tenders £300m framework

Up to five firms will carry out upgrade and newbuild work at three campuses
2 days ago

Work starts on Manchester 26-storey Obsidian tower

Contractor Domis starts Salboy's 10th Manchester scheme in seven years
2 days ago

Race for £1.3bn West Midlands social homes framework

The Community Housing Group reboots tender race for new build housing
2 days ago

Delancey submits £400m King’s Cross lab plans

200,000 sq ft lab/office project will be built above railway and tube tunnels just 4.5m below
3 days ago

Winners revealed for £150m fire safety framework

New deal will help organisations comply with the Building Safety Act
2 days ago

Sellar plans £500m City tower next to Walkie-Talkie

Consultation starts on London 60 Gracechurch Street tower
3 days ago

Severfield ends year on high with record order book

Orders top £500m with strong future pipeline of opportunities ahead
3 days ago

Second senior director exits National Highways

Commercial director Malcolm Dare set to move on to new role
3 days ago

New scheme fuels London lab building boom

Plans in for 160,000 sq ft Whitechapel scheme near Royal London hospital
3 days ago

Contract race starts for next £155m section of A9 dualling

Prior Information Notice published for Tay Crossing to Ballinluig stretch
4 days ago

£55m Sheffield build-to-rent scheme approved

Demolition to start later this year for 158-flat Sheffield Garden project
4 days ago

London back as most expensive place to build in world

Capital leapfrogs Geneva to top costliest construction rankings
4 days ago

Gas supplier Regent to buy TClarke for £90m

£491m turnover listed building services specialist to be sold
4 days ago

Steel contractor Billington launches into bridge market

Steelwork firm hires staff from failed architectural and bridge specialist SH Structures
4 days ago

McGee employees benefit from rise in profits

Pre-tax profit doubles boosting payouts for Employee Ownership Trust
4 days ago

Lendlease veteran is latest new McAlpine director

Paul Sims joins as Operations Director after 40 years at rival contractor
5 days ago

Costain signs site labour supply deal with four firms

Contractor to use only a quartet of providers for temporary labour supply
4 days ago

BAM go-ahead for Leeds 200,000 sq ft office

Latitude Yellow will complete final plot at Doncaster Monk Bridge site
5 days ago

VolkerFitzpatrick wins £30m logistics job

Latest deal to build five distribution units for Prologis UK
5 days ago

Trio win new Scape utilities consultancy framework

Perfect Circle, AtkinsRéalis and Arcadis win places on
4 days ago

Precast firm FP McCann cleared after immigration raid

Home Office takes no action after public raid on construction site
5 days ago

Contractor services