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Innovation Showcase | Track-free travelling formwork drives pace of HS2 green tunnel work

Innovative moving formwork is helping to speed construction of High Speed 2’s Copthall Tunnel in north west London.

Copthall Tunnel is one of five green tunnels being built along Phase 1 of High Speed 2 (HS2) between London and Birmingham.

Situated between HS2’s Northolt Tunnel and the Colne Valley Viaduct, the 880m long reinforced concrete Copthall Tunnel will blend into
its natural surroundings, covered with trees and plants once construction is complete.

The project is being delivered by Skanska Costain Strabag Joint Venture, with Kilnbridge appointed to complete the reinforced concrete works. Making the tunnel a concrete reality has been possible with custom formwork travellers engineered by Peri’s specialist infrastructure team.

As the travellers were expected to be in use over an 18 month period, the main drivers influencing their design were durability, productivity and sustainability.

To support the specified construction sequence, Peri’s engineers designed two carriages which enabled the site team to cast the walls and roof slab simultaneously, ultimately accelerating the programme. These carriages comprised four units in total, two for the wall and two for the roof.

The carriages are designed to reduce material, manual labour and craneage as the main operations such as striking, positioning and travelling are completed hydraulically.

The wall forms are built from special modular steel panels. Each set is designed to build 20m long and 7.5m high walls.

The panels are suspended from a carriage which is designed using off-the-shelf components from Peri’s Variokit range, with some specially fabricated connection parts. Variokit rails provided additional support for the formwork, reducing through ties to less than half the quantity required in a traditional panel system.

“We’ve been able to save around five days per wall in comparison to traditional formwork systems, as we can complete installation and prepare the system for concreting in one day,” says Kilnbridge project manager Teresa Martin.

The internal and external formwork on the wall carriages raise, lower and retract hydraulically, eliminating crane use and reducing labour requirements and cycle time by over 80%.

The roof carriage is built from a mix of special and standard components. In addition to fully supporting the rebar and concrete load, it features hydraulic cylinders which enable the traveller to be lowered, collapsed, pushed under the carriage in front and repositioned to allow rebar fixing and pouring operations to be concurrent. 

Peri senior sales engineer Dan Biggs says: “Special steel formwork was ideal for this project as the forms can be reused up to 30 times, so there is an obvious material saving advantage in addition to time savings, as panels do not need refacing, unlike a
plywood faced system.”

Following on from the installation of the roof traveller, the next steps will be progressing the tunnel so all three elements – base slab, tunnel walls and roof slab progress concurrently without conflicting. Tunnel construction is expected to be completed by February 2025. 

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HS2 will bury two Tunnel Boring Machines at Old Oak Common

Two of HS2’s large tunnel boring machines are to be buried into the site at Old Oak Common next year so they can wait there until a decision is taken about how to build Euston station.

The two tunnel boring machines (TBMs) are needed to dig the two railway tunnels linking Old Oak Common to Euston, but when construction of Euston station was paused earlier this year, there was also the decision taken to delay the two connecting tunnels as well.

Although there’s no practical reason that delaying the Euston station build would require the two connecting tunnels to be delayed, with Euston station effectively on lockdown at the moment it would require the station site to be partially reopened to allow the tunnel portals to be constructed for the TBMs to arrive.

HS2 has also said that delaying work on the Old Oak Common to Euston station tunnels allows them to focus on the section up to Birmingham. There’s also a vanishingly tiny chance that the tunnel’s alignment could be changed to meet up with a redesigned Euston station.

So the two tunnels are also on hold, but to reduce disruption when the two tunnels do start being built, HS2 will drop the two tunnel boring machines into position at the eastern end of Old Oak Common station in readiness for when they are needed.

The two tunnels were expected to start being constructed next year, and as there’s a long lead time on ordering the TBMs, they will be arriving anyway, and installing them into the underground chamber where they will be needed also reduces the headache of storing them somewhere else and then assembling them later.

Placing the TBMs in situ also avoids disrupting Great Western mainline railway in the future, as it will widened as part of the station build, and happens to be running over the top of where the underground chamber needs to be built.

Although it sounds like a major intervention in the plans, and while it is unusual to put a TBM in the ground and leave it there, it’s not unusual to build empty concrete boxes in the ground years, or even decades before they’re needed.

When the Elizabeth line was being built, it made use of the Moor House shaft which was built in 2004 specifically for Crossrail, even before Crossrail was given approval in 2008. There’s also a space under an office block in Victoria ready for when Crossrail 2 opens, and plenty of other examples of holes in the ground being built long before they are needed. All because it’s considerably easier and cheaper to build them early and leave them empty than build them later*, and if they aren’t needed, then there’s a large empty space that will find a commercial use anyway.

The government has committed to opening the extension to Euston, so the TBMs will be switched on. Eventually.

Meanwhile, work carries on to complete Old Oak Common station, with six platforms for HS2 trains and eight at the surface for mainline and Elizabeth line services. Also, an ex-Crossrail tunnel boring machine is about to start digging a tunnel next to the station so that spoil removal and deliveries can arrive without using the roads. Although always required, the logistics tunnel will have added value when the Euston tunnel works start as they will be able to minimise the disturbance to the fit out of the Old Oak Common station.

When Old Oak Common station opens in 2029-33, as it will be the terminus, it’s expected a large percentage of HS2 customers will switch to the Elizabeth line, and TfL is in discussions with the government to secure orders for additional Elizabeth line trains to cope with the large influx of extra passengers.

The date that a modified Euston station will eventually open is not known, but it’s now not expected to be until 2040 at the earliest.

I could add that building the structure for an 11-platform station at Euston and leaving a third of it empty would be a lot cheaper than building a 7-platform station in full and then trying to bolt on a few extra platforms later.

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