HS2 completes 6,200t bridge drive under West Cost Main Line

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The 56m long and 19m wide structure was built adjacent to the WCML at Fulfen Wood, near Lichfield, over the last six months. The build was led by Byrne Bros, part of the BBV (Balfour Beatty Vinci JV) supply chain. It will allow the future HS2 track to run beneath the WCML as it heads north out of Birmingham and towards Crewe.

The concrete structure was slowly manoeuvred into place on a self-propelled modular transporter (SPMT) with the aid of specialist lifting company Mammoet. The 840-wheeled transporter includes four carrier beams and was controlled by a remote steering system.

Mammoet UK lead engineer Peter Shoenmakers commented: “The Fulfen Wood Overbridge installation does show that with a collaborative approach and early engagement with all involved parties during the design stage of the structure, a cost effective and a most efficient installation method can be developed early on in the project.

“The early engagement allowed the designers of the structure to design the bridge that suited the available and existing equipment to be used and no special equipment had to be fabricated or purchased. This approach is very important from a sustainability perspective.”

Roughly 61,000m³ of material was removed over the six months before the operation. In the final days leading up to the bridge drive, when the railway was closed, the team removed the railway track and excavated over 15,000m³ more material to create space for the structure.

The BBV team on the project involved around 300 people, including 200 working around the clock over the last week to move the bridge, backfill around it and reinstate the railway for the WCML to re-open next week.

The operation took place during a nine-day closure of this section of the WCML, known as the Trent Valley line, which commenced on Saturday 15 July. During this time, Network Rail is also carrying out a range of works on the line including railway upgrades and platform works at Lichfield Trent Valley station.

The SPMT used on the Fulfen Wood bridge drive will soon be used on another bridge drive for HS2. This one will take place near Streethay and see a similar 2,600t structure driven into place under the South Staffordshire line between Lichfield High Level station and Derby.

HS2 senior project manager Caroline Warrington said: “This huge feat of engineering – the UK’s heaviest single span bridge drive – is our latest big milestone as we approach peak construction on Phase One of HS2. We’re making fantastic progress on this section of the route, with over 9,000 people working on the project in the Midlands and over 29,500 on the whole project, providing a vital boost for British businesses and jobs.”

Byrne Bros construction director Tom Lyons said: “Byrne Bros are delighted to have been involved in such an amazing project. The BBV team have been fantastic to work with, demonstrating great leadership, teamwork and management of a complex engineering project.”

BBV section engineer Chloe Foster-Chambers said: “As an engineer, big feats of engineering like this bridge drive make HS2 such a fantastic project to work on. It’s been a real team effort over the last two years, and seeing the operation successfully completed felt like a great achievement for everyone involved.”

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