Crossrail – Technical paper on Moorgate shaft base slab

As previously reported, Crossrail now has a Learning Legacy website dedicated to “the collation and dissemination of good practice, lessons learned and innovation from the Crossrail construction programme”. The material, consisting of case studies, technical papers, documents, templates and datasets, is being “shared for use by other major projects and is relevant to clients, corporates, and suppliers from main contractors to small and medium enterprises.”

Recently a technical paper was published on the Learning Legacy website about the design, detailing and construction of the Moorgate shaft base slab – a 1750 m3 pour carried out using Camfaud pumps.

Moorgate shaft base pour

Moorgate shaft base pour

The technical paper makes for fascinating reading, especially in regard to the pour preparations. As the paper concludes: “Careful planning of the concrete pour from reinforcement detailing through to road closures to give access to a constrained site in the heart of the City of London, the contingency measures for disrupted concrete supply and the control of concrete temperature led to the successful execution of what was at that time Crossrail’s largest concrete pour.”

Concrete magazine article – pumping heavyweight concrete

Crossrail C610 - Heavyweight concrete pumping

Crossrail C610 – Heavyweight concrete pumping

The February 2017 edition of the Concrete Society’s magazine Concrete, has an article about placing heavyweight concrete to form part of the Crossrail track slab in central London. The joint venture contractor installing the track on this project is ATC jv (Alstom, TSO and Costain), the concrete is supplied by London Concrete and the concrete pumping is being carried out by Camfaud.

Heavyweight concrete was considered the best option for this section of track bed in order to minimise the noise and vibration generated by the Elizabeth line when it is in service, especially in noise sensitive areas with recording studios above.

The heavyweight concrete used contains MagnaDense, a natural aggregate which is approximately twice as dense as normal aggregate. MagnaDense from LKAB Minerals is formed of black ferrimagnetic natural iron oxide (magnetite) and is mined in Kiruna and Malmberget in northern Sweden.

As the article notes, Camfaud Concrete Pumps chose a Putzmeister BSA2110HP static pump as the main pump, with another high-pressure pump being used as a backup and also to clean the lines using a water wash-out system. The concrete has been pumped through 1100m of pipeline, during which time there was approximately 40 tonnes of material contained in the line.

The same edition of Concrete magazine has an article about the new Medway valley crossing, built by BAM Nuttall to give access to the new 1000 home, Peters Village. Camfaud carried out the concrete pumping on this project too and further information about Camfaud’s work on this innovative bridge construction can be found here.

Peel Ports Great Yarmouth – Outer Harbour Works

Breheny Civil Engineering - Peel Ports, Great Yarmouth

Breheny Civil Engineering – Peel Ports, Great Yarmouth

We have recently been working for Breheny Civil Engineering on their Outer Harbour works for Peel Ports Great Yarmouth. Breheny’s contract is for the construction of primary infrastructure and ground works for the offshore Galloper Wind Farm and East Anglia ONE Wind Farm projects. The contract includes the delivery of a yard storage and marshalling area, as well as the installation of heavy-lift quay facilities.

Breheny Civil Engineering

Breheny Civil Engineering

Last year, ScottishPower Renewables selected Peel Ports Great Yarmouth as its port of choice for the construction and installation activities for its £2.5 billion East Anglia ONE offshore wind farm.

The turbines for the project will be supplied and installed by Siemens, which also announced Great Yarmouth as the assembly and installation base for Galloper Wind Farm which is currently being constructed by innogy SE on behalf of the project partners.

(Camfaud have had another involvement with the Galloper Wind Farm project – pumping concrete for North Midland Construction on their contract to construct a new onshore substation to link the export cables from the wind farm to the National Grid.)

Peel Ports Great Yarmouth

Peel Ports Great Yarmouth

Siemens will supply 56 six-megawatt turbines for Galloper Wind Farm and 102 seven-megawatt turbines for the East Anglia ONE Wind Farm, which will have the combined capacity to generate enough energy for up to 836,000 homes a year.

To showcase the work that they have been carrying out for Peel Ports Great Yarmouth, Breheny commissioned a video which, shows a Camfaud boom pump working to construct an external slab for the yard storage and marshalling area. And, by happy coincidence, the video also shows our sister company Premier Concrete Pumping feeding a CFA piling rig of their customer Bachy Soletanche.

The Breheny video is embedded below:

New Medway Valley Crossing to Trenport’s Peters Village

Aerial view of Medway Valley Crossing

Aerial view of the new Medway Valley Crossing linking to Trenport’s Peters Village

During this winter, Camfaud has been helping contractor BAM Nuttall to construct a new bridge over the Medway valley in Kent. The bridge is being built to provide access to Trenport Investments Ltd’s new residential development of Peters Village, with the road from the bridge joining the A228 at a new roundabout between Snodland and Halling.

In December, Camfaud poured the main span of the bridge. Two M36 boom pumps were supplied and were set up either side of the river on the temporary jetties that had been built to accommodate the plant needed to construct the bridge.

Both of the pumps were equipped with a one side support (OSS) system that allowed them to set up on the narrow jetties. This system made it possible for the pumps to short rig on the off side whilst extending the outriggers fully on the working side. The OSS system prevents the boom from slewing into the unsupported area and so the pumps were completely stable at all times.

The two pumps worked in tandem all day with the concrete initially being placed at the centre of the bridge span. As the pour progressed, the two booms worked outwards thus ensuring that the loading, imposed on the bridge by the concrete, was balanced across the structure.

For this technically challenging and project critical pour, Camfaud supplied two of their most experienced pump operators who, between them, have over 50 years experience pumping concrete for Camfaud.

Medway Valley Crossing from Peters Village side

Medway Valley Crossing from Peters Village side

Pouring the centre span of the new Medway Valley Crossing

Two pumps, working together, to balance the loading on the centre span of the bridge

Two M36 pumps working at the new Medway Valley Crossing

Two M36 pumps working in tandem at the new Medway Valley Crossing