GPL Civil Engineering Ltd

"Safely delivering the UK's Infrastructure"

Final photo 3

Special Projects

M56 Cheadle Branch

Client:  Balfour Beatty Mot MacDonald – Area 10 Motorway Network
Start Date: Phase 1 – May 2013; Phase 2 – February 2014
Duration:  Phase 1 – 12 weeks; Phase 2 – 9 weeks
Value:  £765k
 

SCHEME DESCRIPTION: GPL Special Projects undertook the complete structure refurbishment of the existing M56 motorway bridge over the Cheadle Branch Railway Line working closely with Balfour Beatty Mott Macdonald on behalf of the Highways Agency. The 2nd and final phase of these works was successfully completed in May 2014.

The scheme called upon the skills and expertise of all sectors within the Special Projects workforce and management team.

1st Phase works were carried out below the bridge deck to bridge abutments and bearings adjacent to a live and busy railway line. Rail-side works, during rail possessions by PTS trained operatives to both bridge abutment walls included the erection and dismantling of fixed scaffold access, encapsulation of the scaffold, hydro-demolition of defective concrete andsubsequent concrete repair using spray concrete methods. Furthermore the existing steel bridge beams and paint system known to contain lead were prepared by grit blast cleaning methods to a SA2 ½ Standard, with a new protective coating of Highways Approved Standard applied by GPL’s trained ICATS operatives using airless spray methods. In order to achieve timeframes imposed by Network Rail the works needed to be carried out both day and night to ensure maximum efficiency.Works were managed and coordinated to high standards to ensure all safety critical work tasks were completed without incident. A strict regime of inspection and testing was followed throughout with each sectional completion of work being signed off and approved. Upon works completion, a comprehensive testing and inspection record was issued to the client offering full guarantee of the works in line with the coating manufacturer’s warranties.

The 2nd Phase of the works was carried out at deck level across the motorway carriageways during overnight and weekend lane closures. Works included some minor civils elements; removal and replacement of kerbs, including the installation of new bridge deck drainage kerbs; refurbishment of the central reserve and verge concrete hard-standing. The most challenging aspect of the deck level works involved the removal and replacement of the bridge deck waterproof system. Full carriageway closures during weekend periods from Friday evening to Sunday evening were planned for both the East and West carriageways. During the closures, precision time management for all tasks was needed to ensure the successful hand-back of the busy carriageway, close co-ordination with preceding and follow on trades was implemented. GPL Special Projects utilised the GPL Group’s in-house plant company GPL Plant Ltd to provide the necessary plant supply and support during the weekend closures. Tracked excavators, tower lights, compressors and Hi-ab grab wagons were supplied, delivered and collected from site successfully. GPL Special Projects removed the existing waterproof membrane and asphalt sand carpet by use of excavators; all waste materials were collected and disposed at licensed waste transfer stations by use of Hi-ab grab wagons. The deck preparation works continued by use of specialist captive blast equipment ensuring the concrete deck was prepared to a required U4 Classification. Areas of defective concrete on the deck surface, if discovered could be rectified by GPL’s operatives immediately on-site with additional labour and material on stand-by if required. GPL Special Projects then carried out the application and installation of the H.A.P.A.S. / B.B.A. Approved Matacryl® One Coat Bridge Deck Waterproof System. Re-surfacing works by other contractors followed on as planned with the newly refurbished carriageways re-opening to public traffic without delay.


 

School Lane, Kirkby (Bridge Refurbishment)

Client:  Storey Rail
Start Date: May 2013
Duration:  6 weeks
Value:  £80,000
 

GPL Special projects have recently completed the refurbishment of the Network Rail Structure at School Lane in Kirkby..

By utilising of our strong supply chain, GPL SP were able to offer a complete package to our client. Scaffolding was erected at both sites followed by full Envirowrap encapsulation. Once sealed the area was handed to GPL SP in-house Protective Coatings Division. Our Fully trained ICATS operatives, grit blasted all exposed steelwork to SA2.5 removing all existing lead based coatings. The contaminated waste was handled under strict accordance with current regulations and disposed of accordingly. Once prepared the exposed steel received the M34 paint specification by means of airless spray to give a design life of 25 years. Working under ROR possessions and Line Blocks our PTS trained ICATS workforce carried out ST3 and coating works to the lineside parapets.

Pontymister and Pembroke Bridge Refurbishments

Client:  Birse Rail
Start Date: January 2013
Duration:  8 weeks
Value:  £180,000
 

GPL Special projects have recently completed the multi-disciplined refurbishment of rail bridges at Pembroke and Pontymister in South Wales.

By utilising of our strong supply chain, GPL SP were able to offer a complete package to our client. Scaffolding was erected at both sites followed by full Envirowrap encapsulation. Once sealed the area was handed to GPL SP in-house Protective Coatings Division. Our Fully trained ICATS operatives, grit blasted all exposed steelwork to SA2.5 removing all existing lead based coatings. The contaminated waste was handled under strict accordance with current regulations and disposed of accordingly. Once prepared the exposed steel received the M34 paint specification by means of airless spray to give a design life of 25Yrs. Working under ROR possessions and Line Blocks our PTS trained ICATS workforce carried out ST3 and coating works to the lineside parapets.

In addition to the protective coatings GPL SP fully trained Concrete Repair specialists carried out various masonry repairs on both structures including, stitching, pointing, and re-facing. The use of a trusted sub-contractor allowed steel repairs to complete the scheme along with the installation of new signage.

Although both structures involved a high level of interface with the general public GPL SP ensured they were completed within programme prior to sign off from our client.

Pontymister Bridge Gallery:

Pembroke Bridge Gallery:

Hollins Bridge Street – Blackburn

Client:  Storey Contracting
Start Date: January 2013
Duration:  1 Possession
Value:  £20,000
 

GPL Special Projects were tasked with the Waterproofing and Protective coatings elements to the above structure. As part of a weekend blockade GPL SP had just 10 Hrs to Mechanically Prepare and Paint the exposed surfaces of the box girder followed by the installation of the “Hytec Waterproofing System”.

The ten hours began with GPL’s ICATS trained operatives preparing the steelwork to ST3 by means of rotary and pneumatic hand tools. Extra precautions were required as the existing paint being removed contained lead. The preparation was followed by the application of 3M Scotchcoat paint system.

The painting work was then followed by GPL’s in-house fully accredited “Stirling Lloyd” Hytec Applicators. The entire bridge deck including deck ends and drainage channels were overlaid with a layer of Geotextile 1000. Wall trims were fastened to the painted box girder and sealed with polysulphide sealant, This then allowed the “Hytec 1.5mm” system to be heat welded to the trim and laid over the entire area. The waterproofed deck then received two further layers of Geotextile 1000 to protect it from the freshly laid and compacted ballast.

The work was completed within the desired working window contributing to a successfully delivered scheme.

M57 Brooklands

Client:  A-One+
Start Date:  September 2012
Duration:  3 weeks
Value:  £60,000
 

GPL Special Projects have recently completed this challenging concrete repair scheme for A-One+. Although the repairs were carried out by traditional means the location and access requirements presented GPL with numerous constraints. GPL constructed a floating pontoon and walkway under the bridge, ensuring all safe systems of work were adhered to.

The pontoon was then fully lined with debris netting and sheeting to provide a safe and environmentally friendly working platform. The repairs were carried out with all debris collected, ensuring that no foreign matter entered the water-course throughout the duration of the works. Safety line, live preserves and life buoys were employed to ensure the safety of all operatives.

Mount Sion Footbridge Refurbishment, Radcliffe

Client:  Bury Council
Start Date:  March 2012
Duration:  8 weeks
Value:  £130,000
 

GPL Special Projects has recently completed its first direct contract for Bury Council involving the refurbish of an existing steel footbridge over the River Irwell in Radcliffe near Manchester.

The works comprised surface preparation using both shot blasting and hand preperation techniques; replacement of a number of items of steelwork including parapets, priming of the substructure and superstructure before finally re-painting. The work were carefully undertaken to ensure the integrity of existing services and asbestos pipework. All works were completed from a fully encapsulated scaffold structure spanning the River Irwell with maximum care being taken to ensure that works progressed in a safe and environmetally sensitive manner.

Intersection Bridge, Daresbury

Client:   MPB Structures Ltd
Start Date:   Feb 2012
Duration:   4 Weeks
Value:   £65K

 

GPL Special Projects have recently been awarded the structural repair and refurbishment of Intersection Bridge Daresbury. Spanning the West Coast mainline this Rail over Rail structure necessitates the use of many of GPL Special Projects’ ‘in-house’ skilled trades.

The work comprises the removal of graffiti from the brickwork by means of High Pressure Washing. This is then followed by Concrete Repairs to the main structure and re-pointing of the brickwork.  Surface Preparation and Coatings by ICATS trained personnel to the Rib Ends followed by the application of Anti-Carbonation Coatings. All work is being carried out within a mix of day time and Possession / Isolation working.

Bury Metrolink – Lead Removal

Client:   J Murphy and Sons Ltd
Start Date:   Dec 2011
Duration:   10 weeks
Value:   £130K

 

As part of GPL’s Metrolink Refurbishment, GPL Special Projects were employed to carry out the removal of existing ‘lead based’ coatings from Bury Metrolink Station.

The station required being open to the public each morning and therefore UHP Washing was the method employed for surface preparation.  All contaminated paint was removed from the existing steel, collected, and disposed of on a nightly possession basis. The Steelwork was then overcoated with a three coat system. GPL managed the contract and ensured that the station was re-opened every morning with no delays to the Network.

Peel Brow and Fletcher Bank (M66)

Client: Aone +
Start Date: Oct 2011
Duration: 3 Weeks
Value: £70K
 

Peel Brow and Fletcher Bank are two structures located on the M66 Motorway. GPL Special Projects in-house Concrete Repair teams were employed to carry out over 30 m2 of structural repairs in a live Motorway night shift environment.

The works comprised of Hydro Demolition and mechanical breakout, the grit blasting of exposed rebar followed by the reinstatement of repair mortars. The reinstatements combined both sprayed concrete and hand placed mortar. All of the work was carried out within fully encapsulated scaffolds on either side of the carriageway.

Irwell River Park Improvements

Client: GallifordTry for Urban Vision / Salford City Council
Start Date: November 2010
Duration: 31 weeks
Value: £225,000

GPL were engaged by GallifordTry Construction to undertake hard landscaping and painting works on a scheme to improve a 2km stretch of the banks of the River Irwell between the Stretford Road Bridge and the Princes Bridge.

The works included the excavation and relaying of sections of paving; jet washing and remedial works to block paving, refurbishment and painting of handrailing and heritage features and the installation of street furniture.

These works were undertaken adjacent to an environmentally sensitive watercourse and also involved maintaining continued pedestrian access throughout the works.

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