Tilbury Docks concrete works

Project Objectives

The project involved carrying out concrete paving reconstruction works at Tilbury Docks, concurrently at two designated areas. The scope of the works included site preparation and breaking out of existing surfaces; the installation of subbase, blinding, and reinforced concrete slabs; drainage improvements including new gullies and manholes; and jointing, sealing, and asphalt fillet works.

This included conducting trial pits and carrying out CBR (California Bearing Ratio) tests to confirm existing services, levels and ground stability, as well as treating any soft spots discovered.

Project Works

In a first for Ryebridge, the works involved the use of a 2m wide concrete planer, a piece of machinery which has only been used in the UK for the past couple of years. This planed out 2,000 sq m of concrete, 300mm deep, in just two days.

All the material was graded as recycled part 1, which meant it was ready to be used elsewhere.

Traditionally a project of this scope would have involved using two or three diggers to break up the existing concrete and then transporting it to a crusher, and would have taken between two to three weeks.

The time saved is a game-changer not only for Ryebridge, but also for the port, where the use of space is commercially crucial, and the project was completed two weeks ahead of the 10 week schedule.

Key Quantities

Subbase and Blinding

• Trim and compact the formation to achieve a minimum CBR of 15%;

• Lay and compact 150mm thick subbase;

• Install blinding concrete layer.

Concrete Slab Construction

• Install 500-gauge polythene membrane;

• Pour and finish concrete slab to the specified thickness and finish;

• Install expansion joints between new and existing slabs.

Drainage Works (Location 2)

• Install new gullies and manholes to E600 specification and connect to existing drainage infrastructure.

Innovation and Best Practice

The works were completed two weeks ahead of time, and on budget with 100% safety record.

All works were completed with no disruption to port operations, with the designated areas cordoned off with secure fencing.

All required machinery was mobilised and maintained on site, and a dedicated team oversaw health and safety, quality and progress throughout the works.

The innovative and successful use of a concrete planer means this approach will be used on future jobs elsewhere, ensuring Ryebridge brings this best practice approach to other projects.

Experience of working in port environments and managing a significant volume of subcontractors is essential. In addition to this, gaining such knowledge over time spent completing these works has reinforced our ability to plan for things that would not be expected.

Ryebridge is always solution-focused, adaptable and client-centric.

London Luton Airport International Departure Lounge mezzanine floor

Project Principles and Objectives

The construction of a new 675 sq m mezzanine floor above the second floor IDL, supported by a steel structure coming up from the baggage area, rising through the ground floor and check-in area up into the IDL area.

In addition to the design and build of the mezzanine floor, Ryebridge was also contracted to strip out the fixtures and fittings left behind following the vacation of Unit 18 by Frankie & Benny’s restaurant chain.

Project Works

• Work involved hand-digging the new foundation base and shovelling the soil onto a conveyor belt which discharged it into electric motored wheelbarrows to walk out to the skips.

• The foundations for the steels were increased to make them more structurally robust and the steels were then pulled through check-in, through the IDL and up to create a support for the new floor.

• Penetrations in the floors and ceilings took place at night, ensuring the steels could be set in one shift after being transported into the empty check-in area.

• Challenges included reducing the security inspection area, ensuring that baggage handlers could operate adjacent to works and have access to baggage chutes, and preventing vibration and dust from operations interfering with the baggage trolley system.

• To ensure there was a steady flow of material in both directions the team erected an 8mx4.5m loading bay outside the level 25 external shutter which could take a safe working load of 32 ton.

• All construction material was delivered onto this bespoke scaffolding platform during the day, ready for the team to use at night and replace with any waste produce which would be removed on days.

• The 8.5m tall steel framed lift shaft was manufactured in just two sections and carefully wheeled on its side along the corridor where the site hoarding had to be dismantled to bring it in. It was then welded together on site and lifted as one piece.

• Creating the fire escape route from the new mezzanine meant the existing radio communications room (which communicates with the aeroplanes and tugs) had to be relocated. A new radio comms room was built and the communication racks moved over one at a time at night to ensure flights could take off in the morning.

• For the strip-out of Unit 18, the site was hoarded off and work carried out during normal working hours. However, the installation of temporary works and remove of strip-out materials, fixtures and fittings was carried out during the night shift.

Best Practice and Innovation

LLA described the work as “the most logistically challenging construction project ever undertaken in the terminal”.

This complex and extremely technical project was delivered in partnership with the LLA Development Team, and required collaboration with designers, structural engineers, sub-contractors, airside operations, airport security, airport technical services, terminal duty managers and airport concessions.

• All concrete recycled and reused;

• Solution-focused customer first approach, relying heavily on early engagement with client and an honest and open approach to any challenges as they were identified. We took the time to understand the needs of our client and kept this at the centre of our planning;

• Collaborative and innovative strategy with airport operations to allow for work to be completed in a safe and timely manner while leaving airport movements unaffected;

• The works for each phase and handover were complete on time, on budget with 100% safety record.

Bristol Airport West Apron

Project Principles and Objectives

Ryebridge was awarded the project by competitive tender in December 2024. The project completed the new West Apron on the site of the old airside storage area and bus charging station.

The project was central to the strategic growth of Bristol Airport and involved site clearance, relocation of airside fence, new drainage, surfacing and lining, remediating existing stands, electrical works including new HML, FGP (fixed ground power units), sidewinders and lining.

Project Works and Key Quantities

The commencement of the works included the full site clearance including the footings from the old storage. All material was set aside to be crushed and recycled for use in the construction phase.

The project involved creating a new West Apron on the site of the old storage area and bus charging station. On top of this Ryebridge installed a new emergency water tank holding over 220,000l of water future proofing airside operations.

The project was in the critical path and high levels of planning and liaison were required with security, airside operations, engineering and the excellent project team led by Tim Goodman supported by Quantum, Hydrock and Chase Consulting.

As part of the site set up Ryebridge installed a temporary airside fence which facilitated easier access as the project became landside.

In just one day more than 1,000 tonnes of asphalt was transported airside and the project itself required over 200 temporary passes. After the stands were completed, the boundary fence was moved and planes were on the West Apron stands just days later.

Quantity of works:

• Site clearance and set up

• Removal of footings from old storage and recycle for fill material

• Dig to formation and lay and compact sub base

• Drylean concrete 234m3

• Surface water drainage (Slot Drains)

• Install 2 new High Mast Lights

• 2 X Ground Power Units (GPUs)

• Plane and resurface stands 34-39

• New acoustic airside fence

• Airside lining

Temporary Drop Off Zone (TDOZ) at London Luton Airport

Project Principles and Objectives

The TDOZ was an LLA project initiated following the fire and collapse of the multi-storey Terminal Car Park 2 in October 2023 - which originally included the DOZ.

Constructing the TDOZ was deemed to be time critical due to the loss of revenue caused by the multi-storey car park fire.

The Mid Stay Car Park was being used as a temporary facility, but the walk from there to the terminal takes about 10 minutes and was therefore not ideal for passengers.

The new TDOZ was planned for the front of the terminal area, the CTA (Central Terminal Area) and involved the relocation of the existing taxi rank, the diversion of the pedestrian walkway into the airport, a new car park for the DOZ, new street lighting, a new traffic system, a new barrierless payment system using ANPR (Automatic Number Plate Recognition), plus new signage, lining and street furniture.

The project had to be phased in such a way as to keep the bus terminal live with no delays, while also ensuring the relocation of the taxi rank without disruption, and keeping easyJet, goods in waste away and the executive car park fully operational.

As well as the TDOZ construction, Ryebridge had to work concurrently on widening the existing pedestrian walkway to the airport, repairing the worn Easy Way.

loop, and building a new sheet pile retaining wall with a gabion basket faced in front of it to allow the road into the CTA to be shifted over to create space for the new TDOZ.

Project Works

• Relocation of existing taxi rank

• Diversion of pedestrian walkway into the airport

• New car park for the DOZ

• New drainage including attenuation tank, interceptor tank and permeable paving in some areas

• New street lighting

• New traffic light system

• New signage and lining and street furniture

• New barrierless payment system, working through an ANPR system

Innovation and Best Practice

At Ryebridge we pride ourselves on our solution focused and customer first approach. We understand that our success depends on our ability to deliver projects accurately, on time and to budget.

Our attitude to delivering solutions relies heavily on early engagement with our clients and an honest and open approach to any challenge as it presents itself.

Our longevity and success has been built around close and long-term working relationships with our clients.

Ryebridge had to complete all three projects at the same time in a very restricted time frame. In order to achieve this accelerated timescale Ryebridge implemented a bespoke working programme, which included numerous gangs working in different areas at the same time, 12 hour shifts operating seven days a week, rapid procurement of necessary materials, and utilising knowledge gained from enabling works and site investigations.

The staff working on the project were also familiar with the area, including any existing constraints and the need to be mindful of pedestrians, vehicles and other stakeholders.

Innovative practices and experience were employed to create detailed traffic management and phasing plans. This was supported by early engagement with all operators and stakeholders while ensuring full operational use for the airport as a business and for passengers, staff and customers.

Marchwood military port redevelopment

Project Principles and Objectives

The site is the home of the MOD military sea mounting centre and although it will remain the hub of the military sea movement, the site is being developed further to allow for the offloading and storage of vehicles and goods to free up space in the port of Southampton.

Ryebridge was awarded the project by competitive ten-der in November 2023 and tasked with carrying designing and constructing a vast vehicular storage hard-surface area with all kerbs, surfacing, drainage, ducts and manholes, including 18 acres of parking facilities.

The project, which got underway in October 2023, involved the demolition of existing site buildings and off-site highway upgrades, including the old armoury and security buildings, alongside the realignment of the internal highway network and upgraded railway crossing points, and the installation of new high mast lights, site CCTV and the electrical infrastructure.

Project Works and Key Quantities

Ryebridge was tasked with creating a design for the new entrance to the port together with a new security building, traffic management car parking and high and heavy load areas.

The main challenge was the short period allowed for construction and the flexible nature of the port, meaning we needed to design paving strong enough to take not just cars and HGVs but in some cases tanks and armoured vehicles.

• 1600 linier meters of storm water drainage.

• 2000 linier meters of new pre-cast slot drainage.

• 3 new interceptors.

• 188m/Cu of attenuation in the form of 2 tanks. 6282 meters of fibre reinforced concrete to a new high and heavy area.

• 15.4 acres of car parking.

• 3.6 acres of HGV parking.

• 15 new high mast lighting columns.

• 26,000 tons of type MOT type 1.
  

Innovation and Best Practice

The use of prefabricated buildings in lieu of traditional building saves on waste and makes the installation time on site quicker, removing numerous deliveries to site.

The use of pre-cast concrete slot drains in lieu of traditional Aco slot drains saved a lot of time on installation.

Installing fibre reinforced concrete to the high and heavy area removes mesh, allows larger bays, and saves time on installation and labour.

In a company first for environmental excellence, Ryebridge transported the 13,000t of material needed for the work on two boats, eliminating 3,800 lorry movements and the generation of 307 metric tonnes of CO2 emissions (based on 25 tonne vehicles each travelling 10 miles).

Although this meant double-handling the material as it was loaded onto and off the boats, it was deemed to be worth the effort to ensure there was minimal impact on the local community.

New Addington swimming pool demolition

Project Works

Ryebridge was tasked with demolishing the disused New Addington swimming pool and community centre in Croydon, and clearing the site ahead of future construction.

Starting on site in April 2023, the brief from Croydon Health Services NHS Trust was to prepare the land ready for work to begin on a drop-off and pick-off point for a new NHS diagnostic centre.

The building, which dates back to 1963 and had been closed for years, was full of asbestos, so the work was logistically difficult, especially as there was a live leisure centre operating next door.

The Ryebridge team ensured there was full dust suppression to avoid any inconvenience for neighbouring residents as well as leisure centre users and staff, especially when bringing down the chimney.

All material stayed on site and was used for infilling, avoiding the need for it to be transported elsewhere, and Ryebridge left behind a flat and empty site when work concluded at the end of June.

Project Principles and Objectives

The project involved the removal and disposal of all asbestos from the site to a licensed facility.

Water was removed from the swimming pool, together with any other debris, and the utilities were capped off.

Demolition took place of all buildings down to ground level, including the ground floor slab, and all material was removed from the site.

The swimming pool walls were then broken up and removed, and the space filled with recycled material capped in layers to a level of 150m.

Any vegetation was cleared from the site, and any rubbish, scrap metal, lumps of concrete and bricks were removed.

Bartlett Square regeneration (DART entrance)

Project Works

With the DART Terminal due to imminently open, Ryebridge was engaged by Luton Borough Council to install the access road and paths and public realm areas to allow access from Kimpton Road for the public by footpath and buses on the road.

As well as public realm paving works, the project involved drainage, electrical and street lighting, CCTV and Hostile Vehicle Mitigation (HVM) barriers to be installed along the whole perimeter of the works.

Project Principles and Objectives

The initial plan for this project was to open the DART to the public using the footpath and buses accessing the turning area as quickly as possible. However as the project progressed and designs were reviewed this changed changed from doing the minimum to ensuring all the following were achieved:

• Appearance: The space needed to present the best possible visuals to the public accessing the DART station:

• Security: The whole area needed to have Hostile Vehicle Mitigation barriers installed at any possible access to the DART;

• Electrical and communication – There needed to be increased collaboration between various stakeholders, including UK Power Networks, BT, the DART CCTV operator, Luton Borough Council CCTV and LBC street lighting teams to ensure the finished project had the correct apparatus working to deliver the streamlined service required.

This meant there was significant change to the initial project, requiring Ryebridge to adapt the work in order to ensure the highest level of quality was achieved.

The original contract value was approximately £800K, but the project finished at £2.6m.

Project Quantities

• Bulk excavation and disposal: 2,813.50m3

• Tarmac surfacing: 5,621m2

• Block paving: 1,480m2

• Kerbing: 1,000m

• Infiltration drainage tank: 360m3

• Drainage runs: 617m

• Pump station: 2no.

• Electrical and CCTV ducting: 3,634m

• Counterterror blocks: 41no.

• HVM raising bollards: 15no.

Collaboration and Design

The designer for this project was WSP (although they were bought out by CAPITA during the lifecycle of the works) and Ryebridge was not responsible for any of the design works.

However, we soon realised that if we did not facilitate collaboration and bring all of the relevant parties onto the site to run through key issues together, the project would stall and might not get delivered at all.

As a result we were able to work beyond the initial scope to ensure the successful delivery of what was a very challenging project. We were able to utilise our local knowledge and network of key collaborators and supply chain to ensure this project was successfully delivered

London Luton Airport Gate House 5

Project Principles and Objectives

Gate House 5 is the primary vehicle access point into the critical part of the airport and the only access point for refuelling tankers. The existing facility had outlived its useful life and was no longer fit for purpose.

LLA sought a specialist design and build contractor to develop an existing concept design through to installation and operational handover of a new fit-for-purpose two-storey facility. Works were to be delivered in such a way as to minimise disruption to the operation by use of a temporary gatehouse or similar for the duration.

Project Works

The biggest challenge faced by Ryebridge Construction was replacing the airport security gatehouse without closing the access gate it serves as it was the only airside access point for fuel lorries.

Diverting fuel lorries to other gates was not an option because as they operate solely on a private road they don’t have road licences.

LLA originally proposed a traditionally constructed building, but Ryebridge realised that not only would this require approximately 12 sub-contractors - all of whom would need security clearance - but there just wasn’t enough space to store necessary materials.

In addition to this, the work would have been subject to inclement weather and would have taken several months to complete. The solution was a modular building constructed in eight components off site and then craned into place over the course of one weekend.

Most of the fit-out, including the kitchen and toilets, had already been done by modular company Texo, so it was just a case of slotting it into position over the groundworks Ryebridge had completed in advance.

Meanwhile, in order to allow for the demolition and removal of the original, not-fit-for-purpose gatehouse, a temporary facility was installed on the other side of the access road, allowing it to remain open throughout the course of the project.

The resulting two-level gatehouse is completely security compliant and CAA approved, and also offers more comfortable surroundings for staff, including extra toilet facilities and a shared space for them to use on downtime.

 Innovation and Best Practice (VE)

By using a modular construction we provided an eight-week saving on the project, and minimised disruption to the operational demands of this busy gatehouse.

The project was secured by competitive tender and was delivered on time and to budget.

Rocket Padel Battersea

Project Principles and Objectives

Ryebridge Construction helped create the new Rocket Padel facility at Battersea Power Station, which showcases a unique four-court club in a bespoke 11-meter-high glass building overlooking the River Thames.

Ryebridge was responsible for all the groundworks on the site, which was the former contractors’ compound for the redevelopment of the iconic power station, used for site cabins, materials and parking.

The eight-week project saw Ryebridge oversee the foundations, the drainage, the base and all the civils, ready for the glass and steel structure to be placed on top, and the job was completed on time without any problems.

Project Works and Key Quantities

Underpinning works to existing retaining wall 8 nr – approx. 38m3 concrete

Reinforced concrete upstand 47mtr long

Waterproofing to existing retaining wall – 26m2

215mm thick retaining wall – 40m2

Sawcut existing reinforced concrete slabs 500mm deep breakout trenches  206m

Drill and dowel existing 500mm slabs; lay mesh and concrete infill 25mm thick trenches – 57m2

Install slab extension 250mm thick including edge formwork, waterproofing; dowel bar connection to existing - 420m2

Install new 150mm drainage 135m

New service trench installation 150mm ducts – 150m

Aco drainage – 40mtrs

Connection into existing manhole 1nr

Realignment of existing pedestrian route – 20m

Installation new crossing point including kerbs, tactile paving – 5m2

Grouting base plates for new structure - 28nr

Tarmac to new access route – 200m2

Scabble and install concrete to existing slab to deal with levels – 350m2

Innovation and Best Practice (VE)

Ryebridge recycled all waste material onsite and reused the stone as the sub base for the works.

 Moving Forward

Ryebridge has worked with the client on other Rocket Padel projects elsewhere in the county, including Becton, and is tendering for future work at other locations.

Bristol Airport Foxtrot Fillet

Project Principles and Objectives

The Foxtrot Fillet project was an airside critical works package designed to be delivered on nights with five hour working windows. Ryebridge was tasked with constructing a surface widening area on the Foxtrot curve to increase the size of the safe trafficking area for airplanes. The construction was full-depth and the project also included edge light relocating and lining.

On the first night we removed the edge lights and stripped the top soil, removing all material from the site as in an airside environment nothing can be set aside. At the same time, following the soil strip, we imported the required stone to ensure the excavated area was at the right height, thereby de-lethalising the taxiway so it was the same level as the runway.

Over the following nights we removed the stone and laid Dry Lean Concrete to build to the right level, we then began the surfacing courses with binding and subsequent wearing. There was more significant works at the tie-in to existing where we planed and resurfaced.

Finally, the Ryebridge team also relocated the edge lights and lined the taxiway and cleared the site.

Project Works and Key Quantities

• Removal of 124m3 of top soil;

• Imported 233 tonnes of stone;

• Laid 90t of Dry Lean Concrete.

Innovation and Best Practice (VE)

The works for each phase and handover were complete on time and on budget with 100% safety record.

All works were completed with no disruption to airport operations, despite the complications of working airside with the need to arrange passes, escorting and security, with the site cleared by 4.30am every night ready for inspection.

Experience of working in airside environments and managing a significant volume of subcontractors is essential. In addition to this, gaining such knowledge over time spent completing these works has reinforced our ability to plan for things that would not be expected. Ryebridge remains solution-focused, adaptable and client-centric.

DP World slot drain and concrete works

Project details

To remove in situ pre-cast concrete slabs, break out defective drain and install new Gatic and brushed finished concrete slabs.

Project Principles and Objectives

The project had a tight programme and working in a busy live operations yard. Defective drainage was causing flooding and external damage and needed urgent repairs. Ryebridge was tasked with removing the adjacent 2m x 2m pre-cast concrete slabs and braking our removing and disposing of existing defective drainage.

Project Works and Key Quantities

· Removal of 800m2 of pre-cast concrete slabs;

· Removal of defective drainage and kerbs;

· Concrete- 800m2 of 300mm mesh reinforced brush finished concrete;

· Drainage installation of 123mm of 225mm and 300mm Gatic;

· Installation of 123m Marshals HB2 kerbs;

Innovation and Best Practice (VE)

With a relatively low scope and tight programme opportunities the VE were limited. The biggest risk was the lead time for the drainage material at two-three weeks and programmed completion being four. We resolved this by laying slabs in areas where the Gatics could follow on. We also added weekend working and longer days to ensure success.

Moving Forward

The success in this project reinforces our commitment to innovation, flexibility and close working relationships with all stakeholders. This was an extremely tight programme in a busy working area, but was completed without any disruption to operations.
Our clients can be certain that we have their objectives at the centre of what we do. In this particular project we are extremely proud that our ability to build relationships and add value to our clients is evidenced successfully throughout the works.
We are keen to continue developing our relationship with DP World and take on further work for the client.

Deddington saltbarn

Project Principles and Objectives

Ryebridge was awarded the project by competitive tender in August 2023 commencing with a pre-construction services agreement.

The project was secured following a tender invitation via the Crown Commercial Services framework agreement and was for Ryebridge to provide full design services and for the submission of a full planning application, including the appointment of all necessary environmental, tree and noise specialist sub-consultants to comply with the requirements of the planning authority.

The main objective was to complete the design and construction of the saltbarn by a deadline of October 1 2024 to ensure that the delivery and storage of road salt to the barn was ready for county road spreading by Highways Depot gritter lorries no later than the middle of October.

Following the submission of the planning application it was uncertain whether planning permission would be granted in time for the construction works to commence without compromising the completion date, but the Ryebridge team did everything in their power to ensure the deadline was met.

Project Works and Key Quantities

The commencement of the works involved the breaking up and disposal of the reinforced concrete slab foundation to the area where the road salt was originally stored, and the removal of any surplus spoil and concrete from site.

Simultaneous to the enabling works, the surface water drainage installation was commenced including all necessary trenching, construction of manholes and the attenuation tank.

Following the receipt of full planning approval and discharge of the planning conditions, work commenced on the structural steelwork frame with the installation of the pre-cast concrete walls.

These works were followed by the timber purlins and cladding and the single sheet roofing, plus the gutters, ventilated ridge and PV solar panels. The final works to be completed were the electrical installations and the saltbarn door.

Project quantities:

• Site clearance and set-up, ensuring permanent access for the operation of the Highways Depot.

• Breaking out of the existing foundations and reinforced concrete slab to the footprint of the new saltbarn, followed by the removal of surplus spoil and debris.

• Demolition of a small office building following inspection and approval by environmental consultants.

• Construction of reinforced concrete raft slab (300mm thick, 580 m2) and foundations to the new saltbarn. Design fabrication galvanising and erection of structural steelwork frame to the saltbarn and adjacent washdown gantry (38 tonnes).

• Supply and erection of pre-cast concrete wall (388 m2).

• Supply and fixing of treated timber purlins and external cladding.

• Supply and fixing of a single skin steel PV coated roofing sheet (660 m2), with gutters and downpipes.

• Supply and Installation of solar PV panels to the roof and connection to the National Grid.

• All electrical installations, including internal and external lighting, fire alarms, lightning conduction, small power.

• Surface water drainage including all trenches, pipework, manholes, attenuation tank and connection to main surface water network.

• Tarmacadam paving.

Innovation and Best Practice

Ryebridge was to ensure programme certainty due to the saltbarn being required for handover no later than September 30 in time for the delivery of the season’s road salt on October 1. Ryebridge succeeded in this fast-track assignment by using capable, committed and proven sub-contractors.

• Ready-mix reinforced concrete was handlaid to ensure quality and best practice.

• Solution-focused customer first approach, relying heavily on early engagement with client and an honest and open approach to any challenges as they were identified. We took the time to understand the needs of our client and kept this at the centre of our planning.

• Collaborative and innovative strategy with highways operations to allow for work to be completed in a safe and timely manner on a live depot while leaving transport movements unaffected.

• The works for each phase and handover were complete on time, on budget with 100% safety record.

Moving Forward

Following the successful design and delivery of the saltbarn, Oxfordshire County Council sent another project enquiry to Ryebridge.

Ryebridge has assisted the council in submitting a full planning application for a new office building for the Deddington Highways Depot. The building comprises a gross external floor area of 199m2 on two floors to replace the existing facility, including new foundations, drainage and services.

This planning application has been approved by Oxfordshire planning authority which will now kick-start the tender process by the client. Ryebridge is hoping to be awarded with this new opportunity and others with Oxfordshire County Council following the success of the saltbarn works.

The project should also highlight to other councils the cost-saving benefits behind a reasonable and measured investment in a saltbarn, as Oxfordshire County Council will recover the cost of the barn relatively quickly in terms of the wasted and unusable salt, and could result in similar works for Ryebridge at other local authorities.

The original site used for grit before construction of the saltbarn.

Bristol Airport Eastern Apron Phase 2

Project Principles and Objectives

Ryebridge was awarded the project by competitive tender in July 2022. The project was Phase 2 and completed the new East Apron on the site of the old airport terminal building.
The project was central to the strategic growth of Bristol Airport and with the completion of the new stands 17 and 18 the airport would be then able to make operational stands 19 and 20 which had been storage areas since 2019.
The Phase 2 works also included a new Alpha Lead on and two new stops bars and a reconfigured and updated AGL system. The AGL works also included a new centreline.
All of this was required to facilitate the use of the four stands. In addition to this stands 15, 16 and 17 were severely degraded with continual defects and increasing risk of FOD. Ryebridge were contracted to plane and resurface this area whilst not impacting on the operations of the airport.

Project Works and Key Quantities
The commencement of the works involved the full site clearance including the footings from the old terminal.
All material was set aside to be crushed and recycled for use in the construction phase. In addition the enabling works included the demolition of the old Swissport tower.
As part of the site set up Ryebridge installed a temporary airside fence which facilitated easier access as the project became landside.
The AGL works due to it being within the airfield was undertaken on nights and Ryebridge worked concurrently on nights and days to accelerate the works.
The nightworks included a rockwheel to core for the stop bars. High mast lights were installed and airport specified acoustic fencing.

Project quantities:

• Site clearance and set up;

• Removal of footings from old terminal and recycle for fill material;

• Demolition of Swissport tower;

• Dig to formation and lay and compact sub base;

• 23,500m3 of PQ concrete;

• Surface water drainage (slot drains);

• Pit and duct systems for high masts and AGLs;

• Install four new high mast lights;

• Two ground power units (GPUs);

• New airside retaining wall;

• Plane and resurface stands 14-17;

• New acoustic airside fence;

• Airside lining

Innovation and Best Practice
The concrete footings from the old terminal were crushed, screened, recycled and used as fill material therefore reducing emissions, cost and time.
To ensure programme certainty and no impact on airside operations Ryebridge rockwheeled the new stop bars in one night each.
Concrete was handlaid to ensure quality and average pour was 250m3 per day.

Moving Forward
Ryebridge is still active at Bristol Airport and has completed other airside projects such as a new airside road for the fuel farm project

Curium Stands and Echo Taxiway reconstruction

Project Principles and Objectives

The project was in three works areas:

●       Works Area A: The development of four new serviced code C stands alongside Taxiway Delta, including ground support equipment (GSE) parking areas and airside road access to the existing south stands, to the existing east apron and to the existing road crossing across Taxiways Delta and Foxtrot.

●       Works Area B: The development of three new serviced code C stands alongside Taxiway Echo, also including provision for parking of 2 code E aircraft (one on the new stands, and one on the existing north apron stands). This also included the realignment of Taxiway Echo, the reconfiguration of the north stand markings, the installation of new fillets to Taxiway Delta and stand 61, the reconstruction of existing pavements forming the failed central section of existing Taxiway Echo and the provision of airside road access to the existing stand 80, road crossings across the realigned Taxiway Echo and Taxiway Delta (towards the cargo apron and hangars). Works adjacent to Harrods Stand 71 retaining wall scheduled for construction throughout August 2022 to minimise disruption to operations.

●       Works Area C: The reconstruction of the remainder of the central section of Taxiway Echo to replace failed concrete bays and to strengthen the taxiway as necessary to resolve the continual failure of this length of taxiway.

Project Works and Key Quantities

The project was deliberately phased to reduce the impact on airport operations, with the biggest challenge always being access to work areas due to security restraints. This project required more than 2,000 vehicle movements with an estimated volume of 18,000m3 of concrete needed airside.

Ryebridge has over 50 full pass security-cleared operatives but through experience gained in over 15 years working airside we planned the following to make access easier:

●       Both sets of stands were made landside with agreements put in place with airport security and the CAA.

●       All concrete that was broken out was recycled and reused as fill material.

Associated works included high mast lighting, fixed ground power units, airfield ground lighting (AGL), and drainage including attenuation tanks, interceptors and penstock pumping chamber to facilitate de-icing stations on the stands.  In the initial phase to facilitate Delta there was a large retaining wall installed between the South Stands and Delta Stansa, which was approximately 2.5m at the highest point.

Both stands also required new fire hydrants and Ryebridge was responsible for installing and designing these.

Ryebridge also completed fencing, lining, saw cut and joint sealing of concrete, on top of upgrading Taxiway Delta AGLs to LED.

Echo Taxiway has previously failed and Ryebridge was responsible for the design and build of a new Taxiway.  This is now in full operation with no defects to date.

The reconstruction phase required the airport becoming a cul-de-sac as the works meant there would be no route through Echo. Without any alternative access available, Ryebridge phased the works to ensure there would be no impact at all on airfield operations and plane movements.

Ryebridge also managed the close-off phase including the Health and Safety file and the O&Ms.

●       6,000m3 wet lean

●       12,000m3 PQQ 450mm

●       10,000 (est) 40mm dowel bars

●       1,000m slot drains

●       New pit and duct for AGLs

●       7 FGPUs

●       5 High Mast Lights

●       3 Fire Hydrants

 Innovation and Best Practice (VE)

●       All concrete recycled and reused;

●       Solution-focused customer first approach, relying heavily on early engagement with client and an honest and open approach to any challenges as they were identified. We took the time to understand the needs of our client and kept this at the centre of our planning;

●       Collaborative and innovative strategy with airport operations to allow for work to be completed in a safe and timely manner on a live Taxiway while leaving airport movements unaffected;

●       The works for each phase and handover were complete on time, on budget with 100% safety record.

Moving Forward

The success in this project reinforces our commitment to early engagement and a close partnership with our clients. Our clients can be certain that we have their objectives at the centre of what we do. We operate exclusively with a small  pool of subcontractors so we can be certain of quality, safety and delivery.

Southampton Port E108/9 Freight Terminal and Rail Extension

Project Principles and Objectives

Ryebridge was awarded the project by competitive tender in July 2022.The objective of the project was to turn 55,000sqm (19 acres) of port area which was formally warehouses, (subsequently demolished) into a multi-use high and heavy freight terminal.

In addition new modular offices and parking area for the operators of the site Solent Stevedores.

Within the site itself was the construction of large bays to facilitate the repair and maintenance of containers. A complete new drainage system for the area was to be designed and installed including four interceptors and 3,000m of Gatic drainage.

To improve the operational capacity of the site when complete, the final phase of the works include a rail extension and platform area.

In addition outside the working area the project also included improvements to West Bay Road and reconstruction of the roundabout between West Bay Road and Western Avenue.

Project Works and Key Quantities

Ryebridge was tasked with creating a design for concrete hard standing to be able to withstand heavy loads in the form of five full containers or seven empty containers. The design standards were Knaptons paving design for ports.

The main challenge was that the site had to be flexible and joints needed to be able to withstand potential point loads of 1240kn.

Ryebridge designed a 370mm fibre reinforced solution with dowels and to achieve the programme poured 20m long bays and averaged between 250m3 to 450m3 of concrete hand laid and brush finished a day.

Project quantities:
Earth Works (Cut & Fill) 14,000m3
Gatic Drainage 3,000m
Concrete (370mm Steel Fibre Reinforced 20,000m3
Tarmac surfacing 3,000m2
Electrical Ducting 10,000m
Electrical Pits 90no.
Retaining Walls 1500m
High Security Fencing 1000m
Interceptors 4no.
New Tarmac Car Park 2,100m2
New high mast lights 4no.
New rail platform 150m

Innovation and Best Practice

The concrete design was developed from mesh to fibre reinforced with dowels to allow Ryebridge to lay a larger volume of concrete a day. The fibre solution removing the mesh saved time and it also allowed for larger bays.

The concrete broken up onsite was recycled and used as fill material therefore reducing emissions cost and time. The rail sidings were pre-cast onsite enabling Ryebridge to remove the need to import pre cast units.

Moving Forward

Ryebridge is continuing to gain experience in ports and is currently working on a major development for ABP at Marchwood Port. The project is the design and build of new automotive storage area, hard and heavy paved areas and S278 works and construction of new security gatehouse.

Hat Gardens Open Lea project

National Building and Construction Project of the Year Award winner

Project Principals and Objectives

Part of the Open Lea project, Hat Gardens saw the transformation of a disused car park into an asset of community value by opening up the concealed river culvert. The project was secured by competitive tender at RIBA stage 3. Ryebridge was to undertake a full design and build including responsibility for three significant risks:

o Design completion.

o Contaminated ground (site investigations had identified this).

o Environmental Agency approval/sign off. All works delivered on budget with all funding milestones achieved.

The car park had been forced to close after a structural defect was identified in the culvert, and although there was a repair budget available, the costs were prohibitively high so it was kept shut and the area became a wasteland. The site was known to have issues with flooding, with risks to nearby housing and businesses if the culvert collapsed, but there was also a sheer lack of green space in the town centre for local residents and workers, so council officers discussed rejuvenating the area by opening up the river and turning it into a park, helping to restore the rare chalk stream which makes up the Lea and tying into a town centre masterplan for the next 20 years. The council identified that the £1.6m scheme could be part-financed using European Regional Development funding, and so it worked up the concept, secured planning permission and opened it up for tender, with Ryebridge Construction winning the bid.

PROJECT WORKS AND KEY QUANTITIES

• Bulk Excavation 1,930m3 • Retaining Walls/Head walls 2no. 30m3 East Headwall and 35m3 West • Gabion Baskets 140m3 • Landscaping 642m2 • Large Trees 7no. • Block Paving 332m2 • Resin Bound Paving 123m2 • Bespoke Stone copings along renewed River Walls 70m • Roads and Taxi Rank 355m2

Innovation and best practice

The works involved removing the existing lid to the river, building new head walls and retaining walls, and constructing new stepped seating and a planted terrace populated with carefully selected vegetation designed to boost wildlife. It was not a standard building project, and part of the work involved diverting the river using piping to access the culvert itself, which was then removed and replaced, forming a new bank and terrace for the river. The scheme involved having to consider adjoining highways and clearing areas of contamination left behind on the site, with Sustainable Urban Drainage Systems incorporated into the design alongside soft and hard landscaping. The project involved close liaison with the Environment Agency to ensure compliance working alongside and over an extremely rare chalk stream. An archaeologist was also present to follow the progress of the excavation works and see if any historical elements were found, adding an extra element to the works.

Moving forward

The site was designed to offer opportunities for various community uses including as a outdoor classroom, a place for mini-concerts, or with a cinema screen on the far bank. The success of the initial project triggered plans for further pocket parks along the river, not only to help with flooding, social impact and wellbeing, but to re-introduce some of the biodiversity and ecological infrastructure back into the town centre. In November 2023 the Hat Gardens was awarded National Building and Construction Project of the Year Award winner. Ryebridge is well placed to deliver these schemes.

Gibraltar Airport Runway Extension

Ryebridge Construction was contracted for this project to Concrete, Saw cut and joint sealing and Manhole construction.

PROJECT PRINCIPLES AND OBJECTIVES

Ryebridge Construction was awarded the contract for the construction of concrete slabs for Gibraltar Airport, secured by competitive tender. Ryebridge has more than 15 year’s experience working in restrictive operationally constrained environments such as airports and this experience was invaluable in successful delivering the project. The fundamental objective was to ensure that the works were successfully completed without any operational impact for the client. The airport was in constant use and ensuring no operations were in any way affected was essential to this success.

QUANTITIES AND SIGNIFICANT OPERATIONS

• Mobilised experienced concrete teams from the UK

• Transported and machinery

• Formwork, manhole construction, concrete, laying and finishing

• Nights concrete works on average 200m3 per night shift

• Saw cut and sealing on days

INNOVATION AND BEST PRACTICE

Experience of working with specific responsibilities in a phased project meant Ryebridge was ideally placed to successfully deliver all works on-time and to budget. Best practice was gained from working in an airside environment where the public and the client meet.

The project also presented the challenge of programming within a minimal mobilisation period and a requirement from the client to gain back possession as early as possible to release the pressure on the existing parking facility.

MOVING FORWARD

The success in this project reinforces Ryebridge’s commitment to early engagement and a close partnership with clients, this ability to build relationships and add value was evidenced successfully throughout the project.

Due to the success and the experience gained from completing this project, in the future Ryebridge will be willing to work more abroad to gain greater experience of working in new environments.

London Luton Airport Soil Screening

Ryebridge Construction was contracted as civils company to cover three phases of consented Environmental Agency permitted screening and compaction works.

Project Principles and Objectives

The fundamental principle and objective of these works were to design and construct a programme across three phases to remediate an existing bunded stockpile. The existing bund was to be tested, screened and repositioned following the highway standard for compaction, drainage and top-soiling. As Principal Contractor, responsibilities included management, compliance and discharge of all planning conditions. In addition to this, the successful engagement, liaison and coordination with the Environmental Agency was a key objective.

Project Works and Key Quantities

The top-level scope of works was to screen the stockpiled excavated material defined as stockpile S1A west. The volume involved was approximately 106,500m3 of material. The soil testing exercise identified hotspots and material to be removed off-site, as well as material that could be placed in a quarantine area and remediated, retested, and then placed in the bund.

Essential key works:

• Install new temporary air-side fence

• Bore holes (36) and soil testing

• Creation of a quarantine hard-standing area with hazardous and non-hazardous waste areas

• Removal of hotspots to go off-site

• Remediated soil to be located in quarantine areas and treated twice weekly

• Screen material and separate wood, plastics, metals and large stone/concrete

• Recycling concrete and stone arising from the screening

• Screened material less than 150mm moved to new bund

• Bund compacted with pad foot roller in accordance with specification for highway works

• Install 150m of 350mm perforated land drain with headwall and catch pits

• Nominal Topsoil covering throughout at a level to discourage habitats and vermin

• Reinstate air-side fence to new position

• Total project man-hours in excess of 10,000 with no accidents or incidents.

• All works were completed on time and to budget.

Innovation and Best Practice (VE)

The remediation strategy was a success, ensuring just four loads left site as hazardous material. The recycled material is available for use on projects around the Airport, reducing the lorry movements on-site and saving cost for the Airport on projects.

Careful planning and sequencing of works minimised the haulage movements on-site. Despite losing nearly a month due to poor weather the reduction in movements ensured no extension of programme.

Terminal Drainage London Luton Airport

The Challenge

The fundamental principle and objective of these works were to design and construct a means to repair a failed section of surface water pipe located within a critical area and 3m below ground level.

The location of the pipe work was such that an innovative and dynamic approach to reconstruction was required with significant operational and environmental constraints.

Scope of Works

The original scope of works included trench excavation for the entire run. This required significant temporary works internally, with structures created within a concessions unit to segregate the works from staff and the public. The temporary structure was to extend outwards with the dig.

Due to the disruption and cost of this approach Ryebridge designed a methodology which not only saved cost and time but minimised disruption to the retail outlets.

This method involving Thrust boring under the landside area travelling the 13-metre distance under the retail unit to a manhole in the main terminal. The project involved an exposed 20m trench at a depth of 3 metres up to the boundary wall of the retail unit from the central search area.

Then the Manhole was set-up with a concrete installed wall to facilitate the Thrust bore for the remaining run under the retail outlet and into the main terminal.

Essential key works:

• Site set-up with noise reducing hoarding and security access gate

• Liaison with airport stakeholders around life safety system, alarms etc.

• Saw cut and break out concrete using electric BROKK

• Machine and hand dig trench to depth of three metres

• On night works remove spoil through terminal. Over 100 tonnes manually removed

• Install trench sheets

• 20 metres new drain run

• Install two new manholes

• Install concrete back-wall for thrust bore

• Thrust bore 13 metres

• Manhole connections

• Reinstate, concrete floor tiling

• CCTV to prove run

All works were completed on time and to budget.