M25 Manhole Bay Replacements

Sector: Highways
Client: Connect Plus Services (Skanska)
Main Contractor: Skanska
Project: M25 Manhole Bay Replacements
Works: Replacing MH Surround Slabs
Duration: 7 Weeks
Value: £130k

This scheme was part of the M25 Maintenance framework contract which TAG construction have been a part of for the last 4 years working with main contractors such as Skanska, Osbornes and Jacksons.

This particular scheme was to replace 6no PQ Concrete bays that had MH accesses integrated in to them on Saturday nights between 23:00 – 06:00. When these bays are replaced over night the working window is only 7 hours before we have to open the road back up to traffic. To ensure these works went without any issues TAG were employed to carry detailed out trials with Skanska.

Each bay was lifted out from the ground by vacuum method and removed from site. The steel reinforcement was placed and the manhole access frame and cover was reinstated before a rapid setting concrete was placed. The concrete was cured in covered tents with temperature controlled conditions.

Under challenging cold conditions these works went without any issues and the road was opened successfully each weekend to the public. The success of these works was down to the amount of pre works preparation that went into each shift and the experience TAG has in this sector of works.

Bexhill to Hastings Link Road – Gabion Retaining Walls

Sector: Civils
Client: Taylor Wood
Main Contractor: Taylor Woodrow/Hochtief JV
Project: Bexhill to Hastins Link Road
Works: Gabion Retaining Walls
Duration: 12 Weeks
Value: £225,000

This project was to Replace circa 465mtrs of gabion retaining walls between 1mtr and 3mtrs high and 7no sections of the highway and walkways. Due to the dangers of excavating on a steep embankment precautious methods had to be adopted to ensure the safety of the operatives carrying out the works.

The client had a tight programme to achieve which was completed ahead of the original programme and on the original budget. TAG and the Taylor Woodrow / Hochtief site teams worked closely to ensure the works minimised disruption to the local highways and walkways.

TAG Supplied all necessary labour, plant and welfare facilities to carry out the replacement works as a package.

M25 Resurfacing Concrete Bay Replacements

Sector: Formwork, Reinforcement & Concrete
Client: Connects Plus, SKANSKA, Osborne
Project: M25 Resurfacing Concrete Bay Replacements
Duration: 3 months

The repair method involves utilising the first night time lane closure for saw cutting the concrete carriageway into sections which are lifted out and replaced the following night. This is done via our Vacuum Lifter; a whole bay is out within a matter of minutes. Dowel Holes are drilled using the EZ slab rider drill that has been designed for applications that call for optimum concrete drilling accuracy. It is an economical option requiring minimal set – up time. Drilling each bay only takes 5 minutes; traditional methods would take up to 1 hour.

The concrete is mixed in-situ and placed using one team per bay. The teams have had to learn to work with the material which acts very differently to normal concrete.

Conventional repairs and materials would take a minimum of 4 nights and 1 day to repair each bay. Using rapid cure concrete and our improved system we currently replace up to 2 bays per night with capacity to do more within the time frame.

The success of the bay lifting procedure using our vacuum lifter has had interest in other sectors such as aviation. We have successfully carried out trials for Ferrovial Agroman at Heathrow Airport which consisted of lifting 500mm deep PQ Slabs within the Taxi-Way and Apron areas.

The process was also trialled at London City Airport for Bay replacements with great success. Not only does it have the benefits mentioned above, it has also been greatly received by the residents around London City Airport for the reduction in noise pollution which the conventional breakout system generated.

Portsmouth Road Cycle Lane Upgrade

Sector: Highways
Client: Kingston Borough and TFL (Kier Highways LoHAC)
Main Contractor: Kier Highways
Project: Portsmouth Road Cycle lane upgrade
Works: Construction of new Reinforced Retaining walls and staircases
Duration: 20 Weeks
Value: £305k

This scheme was part of the cycle highway project for TFL where a social riverside area was to be re-developed for Kingston Borough Council. It was constructed on two sites both offering garden areas for local residents to enjoy at their leisure.

Working for Kier Highways, TAG construction were awarded the tender to construct over 500mtrs of reinforced decorative concrete retaining walls, cast 7no large concrete staircases with stainless steel hand rails, create 4no Cumaru timber decking seating areas, install over 100 metres of pedestrian guardrails and to supply and install many other decorative furniture items.

These works were carried out alongside the groundworks contractor in very challenging conditions. To ensure these works were delivered efficiently and safely TAG developed a good working relationship with the groundworks contractor and Kier site management.

TAG worked very closely with Kier Highways to overcome many challenges that arose from the scheme to deliver a high quality end product for the local area to enjoy.

SAT 1 & SAT 2 Stand Reconfiguration

Sector: Civils
Client: Galliford Try
Main Contractor: Stansted Airport
Project: SAT 1 & SAT 2 Stand Reconfiguration
Duration: 12 Weeks
Value: £210,000

The project at Stansted Airport included the Replacement of Existing PQ bays and construction of new reinforced Concrete bases and Chambers on the main Apron stands Airside. The project included the following items completed by TAG Construction Ltd.

  • Installation of shuttering and formwork
  • Placement of 500m2 of 175mm thick Wet lean concrete
  • Placement of 2500m2 of PQ Concrete
  • Prepare and Place Reinforced FEGP and SEGS bases
  • Construction of a new large reinforced concrete Inspection chamber

These works had to be carried out and handed back in short possessions.

Concrete Bay Replacements – London City Airport

Sector: Aviation
Client: London City Airport
Main Contractor: Tarmac
Project: London City Airport – Concrete Bay Replacements
Works: PQ Concrete Bay Replacements
Value: £1.8m

  • PQ Concrete Bay Replacements
  • Saw Cut and Core existing PQ Bays
  • Break out and remove concrete from site
  • Clean and prepare Bays and carry out any required repairs
  • Pour, Compact and finish bays to 6mm tolerances

TAG Construction replaced up to 8no 5mtr x 5mtr bays on a Saturday afternoon from 13:00 to 19:00 when the airport was closed. All works were carried out airside in high risk areas such as the runway, Apron and taxiways. Each bay was replaced using a high early strength concrete that could be trafficked by aircraft by Sunday 12:00 midday.

Stansted Airport – Divert Stand

Sector: Aviation
Client: Stansted Airport
Main Contractor: Galliford Try
Project: Divert Stand
Works: Construction of Aircraft Divert Stand
Duration: 8 Weeks
Value: £185k

The project at Stansted Airport included the construction of a new Code 4E Aircraft Stand and Lead On/Off. The project included the following items completed by TAG Construction Ltd.

  • Installation of shuttering and formwork
  • Placement of 8500m2 of 175mm thick Dry lean concrete
  • Placement of 8000m2 of PQ Concrete
  • Prepare and Place Reinforced PQ Taxiway service crossings
  • Form a Channel for a new Gatic Slot drain

These works had to be carried out over a short period of time. The programme was achieved with time to spare. All of the concrete was hand laid.

Heathrow Airport – N6 RET Taxiway Reconstruction

Sector: Aviation
Client: Heathrow Airport Ltd (Morgan Sindall)
Main Contractor: Morgan Sindall
Project: N6 RET Taxiway Reconstruction
Works: Reconstruction of a defective concrete taxiway
Duration: 16 Weeks
Value: £595k

These works were part of a scheme to reconstruct a defective rapid exit taxiway linking the main November taxiway to the Southern runway.

Working for Morgan Sindall, TAG construction were employed to carry out the following works as a sub contract package where TAG were responsible for the management and supervision of all works, deliveries, muck away, transportation of operatives and logistics airside to carry out the works below.

Replace 56no PQ Concrete bays. This involved saw cutting and removal of 56no bays where the concrete was taken off site for recycling. The bays had to be cleaned out, repaired using a high spec pre mixed mortar and re-screeded to provide a flat suitable consistent surface for placing the new bays.

Replace the bays pouring and finishing 900m3 of new F6 PQ Concrete to the specific airside specification.

The second part of the scheme was to reconstruct a Rapid Exit Taxiway link. These works involved trimming and compacting the type 1 sub base ready for the concrete pavement. Installation of specific profiled formwork. Pouring 1500m3 of new reinforced PQ concrete pavement over 20no 30mtr x 6mtr bays.

TAG also carried out the reinstatement of the taxiway drainage which included pre-casting 3no new concrete drainage F900 catch pits, installing these catch pits on site and connecting them to the existing drainage carrier drains. TAG Also had to construct a new reinforced concrete base and lay new F900 clearway slot channels with a concrete surround to the taxiway.

These works were carried out over nights and days.

Throughout the duration of the scheme TAG also supplied labour to the main site including specifically training airside taxiway crossing controllers.

Heathrow Airport – Taxiway Reconstruction

Sector: Aviation
Client: Morgan Sindall
Main Contractor: Morgan Sindall
Project: Heathrow Airport – Taxiway Reconstruction
Value: £650k

Scheme 22 works

  • 56no PQ Concrete Bay Replacements
  • Repairs to existing Wet lean layer
  • Local concrete repairs

N6 RET Works

  • Grade and compact type sub base
  • Install profiled formwork
  • Place steel reinforcement
  • Pour new 400mm thick PQ Concrete pavement
  • Precast and install new concrete catch pits
  • Install new slot channel drainage

TAG Managed their airside access and passes for this scheme. TAG also supplied a variety of labour to Morgan Sindall for other site works throughout the project.