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

Aaron Morby 3 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

Reds10 raids house builders for two director hires

David Newey and James Bateman join as regional ops directors
1 hour ago

Builder killed as telehandler overturns

House builder goes into liquidation before court hearing and £160,000 fine
9 hours ago

Firms put on alert for £1.5bn decarbonisation framework

Fusion21 aims to invite bids in January for housing and public buildings retrofit framework
9 hours ago

McLaren boosts building safety and refurb team

Paul Woodhams promoted to newly created MD role at expanding division
12 hours ago

Firms fight to renew places on £450m JV North deal

17 firms face fight to retain places on north west housing consortium list
17 hours ago

Subbies get £7m lifeline on ISG Cardiff schools site

Council strikes deal with administrators and appoints emergency interim contractor
1 day ago

United Utilities names water and waste water design consultants

AtkinsRéalis, Jacobs, Stantec, Binnies, Mott MacDonald, RPS, and WSP make line-up
24 hours ago

Crown Estate in £1.5bn Cambridge Business Park revamp plan

A phased programme of construction will start in 2026
1 day ago

McLaughlin & Harvey returns to profit

Contractor back in the black and looking forward to another positive year
17 hours ago

Graham wins £69m London Stratford flats job

Stratford Mill project will deliver nearly 250 flats
1 day ago

Mace to complete construction of ISG neuroscience centre

Contractor to work with UCL to finish stalled job
2 days ago

BAM finally breaks ground at £60m-plus Yeovil College

Agreed contract price 50% above original estimate on delayed Somerset college job
17 hours ago

Forterra trying to pass on NI cost increases

Brick and block giant writing to customers about 2025 price rises
2 days ago

Refurb contractor Troy Central goes into administration

Suffolk based hotel and leisure specialist had a £38m turnover
2 days ago

Former ISG director joins Wates as regional construction MD

Wayne Flannery joins Wates construction board after nearly 20 years at ISG
2 days ago

McLaren strengthens team for £1.1bn York Central scheme

CEG’s Head of Development (North) Karen Stafeckis joins McLaren Property
2 days ago

ISG collapse brings down glazing contractor

All staff made redundant at Vitrine Systems Limited
4 days ago

Wates gets go-ahead for 235 homes at Cardiff school site

City's first well being village approved
2 days ago

Cost of HS2 bat shed hits £100m

Construction costs revealed for Sheephouse Wood Bat Mitigation Structure
4 days ago

JRL close to deal on sale of stake to Far Eastern buyer

Equity sale plan to strengthen balance sheet and improve liquidity
5 days ago

Andrew Scott wins £22m Welsh hospital roof rebuild

Rotten roof at Bridgend to be replaced after critical incident
2 days ago

Vistry takes another £50m hit on build cost blunders

Second profit warning but problems contained in one division
5 days ago

Watkin Jones go-ahead for Leeds co-living project

Firm will convert former office block Headrow House into 230 homes.
5 days ago

United Utilities hunts for ground investigation specialists

£170m five-year framework deal out to tender
5 days ago

WSP names new chief for UK and Ireland

Paul Reilly promoted to UK president after just over two years at consultant
5 days ago

£125m cash injection for infrastructure at Barking Riverside

Home England funded works to boost 20,000-home development in east London
5 days ago

Groundworks firm Corbyn files administration notice

Court notice lodged by £33m-turnover contractor
5 days ago

Management buyout at joinery specialist TMJ Interiors

Founder James Taylor hands over reins to directors
5 days ago

Subcontractors wanted across the North West

Register now to meet major buyers at Manchester event
5 days ago

Rockwool plans new factory to ramp up output

Stone wool maker plans second factory in Midlands
6 days ago

Contractor services