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.

Luton and Dunstable Hospital Staff Car Parks (East & West)

The Luton and Dunstable Hospital is undergoing a major redevelopment over the next 5 years. The creation of two temporary staff car parks was always part of the plan but due to the pandemic, the car parks became critical due to the volume of patients and staff needing access to the Hospital.

The project was to create two staff car parks in just 6 weeks as these were needed to be in full use by Christmas. This included section 278 works and two new Bell mouth entrances. This is from site clearance through to handover. An exceptionally challenging project where the only chance of success was through constructing both simultaneously.

Project Works and Key Quantities

Works to create these car parks included but was not limited to: -

• Full site set up and compound

• Excavate topsoil strip and site clearance

• Reduce dig excavation to car parking areas and cart away.

• Place and compact sub-base material.

• Drainage installation

• Kerbs

• Section 278 works and two entrance Bell mouths

• Installation of lighting, including construction of bases for columns, installation of columns and associated electrical cabling in ducting

• Car park services CCTV, ANPR, Barriers etc.

• Asphalt surfacing

• Line marking

Designing greater capacity

The original plan by the designers had cars in Car Park B along the right-hand side parked nose to tail. Using knowledge and experience Ryebridge encouraged the client to allow Ryebridge to revisit the design. Ryebridge proposed a reconfiguration of both car parks still allowing for the required two metre lanes creating forty new spaces across both car parks. This increased the capacity of the car parks by 22 spaces at no extra cost to the client.

Runway Duct and Bay Replacements, Bristol International Airport

Project Principles and Objectives

Alongside works at many other UK Airports, Ryebridge has been the Framework Contractor for London Luton Airport for 9 years and their Maintenance Contractor for 10 years. This project involved the essential installation of a new duct under the runway and replacement of 6 defective bays.

Project Works and Key Quantities

Under a runway closure the works needed to be fully completed in two full shifts. The first shift involved rock wheel excavation, duct installation and concrete. The second shift was planing and surfacing.

The defective bays were all replaced in three days with saw cutting, excavating, dowels to adjacent bays, concrete and joint sealing.

Works comprised of:

• Rock-wheeling across Runway for new ducts

• Excavation in soft areas to extend ducts to pits

• Filling and stabilising existing duct with Geobear filling around existing live cable

• Diamond drill into pits

• Fill duct to stabilise – live cable

• Saw cut conc, rock-wheel, angle drill dowels PQ, dig out, concrete

• Angle drill dowels into existing adjacent pavement

• PQ Concrete reinstatement

• Saw cutting and sealing

Innovation and Best Practice (VE)

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 is solution focused, adaptable and client centric.

Following every major project Ryebridge reviews completed works and lessons gained. This process of continuous improvement means every year we are evolving and improving. This application of best practice also applies to our subcontractors. We constantly review subcontractors and while we generally work with a small but trusted group of subcontractors, this changes and evolves to best meet the needs of our clients.

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. In this particular project we are extremely proud that our ability to build relationships and add value to our clients is evidenced successfully throughout.

Manton Lane Footbridge, Bedford

Background

Manton Lane is a busy link road connecting into the A6 towards Bedford from the north. The road hosts retail outlets, industrial units, residential houses and Bedford Modern School. The main site of Bedford Modern School is situated on onside of the road with its playing filed across the road. The road has various crossing points but had been identified for a footbridge for some time due to concerns over high use of crossing points. There were ongoing safety concerns as students congregate on the footpath in large numbers waiting to cross. Ryebridge was awarded by competitive tender, the design, build and installation of the footbridge in late 2019.

Project Principles and Objectives

The programme designed by Ryebridge was to work simultaneously on both plots. Setting up a compound on onside of the road allowing for safe access and egress. Both plots were cleared and secured over a half term break utilizing the quieter time and ensuring that when students returned the area was demarcated. The road closure for the bridge install was completed over a weekend, again to minimize impact on the school and commuters.

Our Approach

The project itself was always going to be challenging with a high volume of stakeholders but was made much more challenging due to the pandemic. This had implications on workers, supply chain and general site management to ensure that all workers kept safe. CITB training undertaken by site team and a Covid Safe site was instigated. There were challenges through outbreaks in the factory and the design team working from home. Our approach was to pro-actively communicate and address and challenges or concerns in an open and honest manner.

Scope of works included:

• Site Clearance

• Piling (32 per side)

• Foundations and bases

• Drainage including soak-away construction

• Bridge tie in to footpath

• Palisade fencing

Under road closure the following:

• Traffic management

• Delivery and installation of deck/stairs supports

• Delivery and installation of bridge span

Innovation and Best Practice

By designing and managing the progamme effectively Ryebridge was able to install the bridge in two visits. The ensure the impact to the School and local users and commuters was negligible. Foundations and bases completed in quarter 4 of 2020. Bridge span at the end of quarter 1 of 2021.

The project was awarded a RoSPA Silver Award, recognising the highest standard of Health and Safety within the project.

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. In this particular project we are extremely proud that our ability to build relationships and add value to our clients is evidenced successfully throughout.

Ryebridge is currently looking to develop its strategy towards securing similar schemes across the UK.

Allhallows, Bedford Public Realm Works

Background

Allhallows Bedford is a busy retail and commercial street based in the heart of Bedford. Allhallows spans from St Loyes through to Silver Street and is approximately a quarter of a kilometre long. It has over 40 retail outlets including cafés, banks, estate agents and essential pedestrian access to Bedford Bus Station. In addition, there are a number of businesses located in the first-floor level and also there are a number of residential flats located along Allhallows.

Alongside pedestrians the site is accessed by vehicles for deliveries and disabled parking.

Project Principles and Objectives

Fundamentally the principle objective was to reconstruct and redevelop the area while still allowing business to trade and pedestrians to move safely around the area.

This is while ensuring deliveries were unhindered to retailers and the bus station and managing waste collections.

Our Approach

Ryebridge developed a detailed and robust plan for the works to include phasing and programme which needed effective communication with all stakeholders.

Prior to taking possession of the area Ryebridge had appointed a communications liaison and a company to manage social media portals to include a closed Facebook Group and Twitter profile. Door to door visits had taken place and a full data capture exercise was completed.

For the first phase of construction there was a 24 hour Gate Man employed while Ryebridge got to understand vehicle movements. In addition there was daily communication via email and face to face visits. Ryebridge took the decision to hire a shop front on the street to operate out of. This facilitated ongoing dialogue and gave retailers and members of the public a place to visit with queries.

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. In this particular project we are extremely proud that our ability to build relationships and add value to our clients is evidenced successfully throughout. Ryebridge is currently looking to develop its strategy for more Public Realm works.

See more details below.

London Luton Airport Goods in Waste Away

In late October 2019 Ryebridge was awarded the construction of a new Goods in Waste Away area at London Luton Airport. The award was by competitive tender and was valued at just over £1m.

Ryebridge has been the Framework Contractor for London Luton Airport for 8 years and their Maintenance Contractor for 10 years. The fundamental principles and objectives of these works were to design and construct a new centralised large capacity Goods in Waste Away area adjacent to the main terminal. The works were carried out in a busy environment while keeping the exiting waste away area live.

In addition to this the area pre-development could not handle large lorries and had a waste away facility that was aged and in need of repair and upgrading.

Project Works and Key Quantities

The works were detailed and complex and required extensive collaboration with key stakeholders, such as airport operations, existing waste away area which needed to be kept live and the bus pick up area close to site.

Scope of works included:

·        Install Hostile Vehicle bollards

·        Construct retaining wall to separate passengers from work area

·        Demolition and removal of old substation room

·        Reprofile surrounding pavements

·        Install new drainage, services inclusive of street lighting data and CCTV

·        New water supply

·        New concrete hard standing area 4,000sq. metres

·        New kerns and PCC edgings

·        Install new screen fence

·        Install new access control barrier system with an airlock system

·        Rising bollards

·        New signage, line marking

Innovation and Best Practice

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 is solution focused, adaptable and client centric.

On this project as it developed it was clear that working alongside the busy bus station was going to be difficult. All works in that area were moved to nights. This ensures that works did not impact on airport operations and pedestrians.

In order to ensure that the waste area could stay live for the full duration of the works we relocated it to a temporary area. This ensured that the service could be maintained, and staff could work unhindered. This included welfare for all staff.

London Luton Airport Runway Maintenance

Ryebridge has been the Framework Contractor for London Luton Airport for 8 years and their Maintenance Contractor for 10 years. The fundamental principle and objectives of these essential repairs is to safely maintain the life cycle of the runway and taxiways with minimal impact on ongoing airport operations.

Works vary depending on the need and Ryebridge supports LLA with an annual review in the summer highlighting repairs required in the Nightworks.

All works to be complete on-time and free of FOD.

Works vary depending on the wear and tear of the taxiways and runways. Annually there is a full airside review with airside operations and works are agreed.

Following this review Ryebridge is given the task of planning the works in full, from integrating with airside operations and runway closures through to work permits, security passes and all required subcontractors.

Most recent works in November included managing over 50 subcontractor operatives, 30 vehicles, security passes access and full onsite management at all times.

Typical works include:

•             Runway and taxiway patching

•             Runway hard shoulder strengthening with a no fines concrete and porous tarmac as there was a carrier drain underneath

•             Re slotting of AGL cables and cans

•             New stop bars

•             Over banding and milling of cracks to asphalt

•             Rubber removal

Car Park Extension at Copse Court, Peterborough

Ryebridge was awarded the contract to deliver the Car Park extension, secured by competitive tender. Ryebridge has over ten years’ experience working in restrictive operationally constrained environments such as airports and this experience was invaluable in successfully delivering this project. The fundamental objective was to ensure that the works were successfully completed with no operational impact for the client. The Police Station and offices were in constant use and ensuring no operations were in any way effected were essential to success.

Experience of working with specific responsibilities in a phased project meant we were ideally placed to successfully deliver our works on-time and to budget. Best practice gained from working in an airside environment where public and client movement is critical in terms of safety and security was employed throughout. Clear signage and walkways were in place and all deliveries and works traffic were managed around the needs of the station and surrounding areas. For the duration of the project the Police Station and other buildings remained operationally sound. The construction of the new car park facility as mentioned was to be delivered in a phased manner and released back to the client for their use on sectional completion. This, along with the demands of working in a secure and sensitive environment, required an open collaborative approach towards delivering the project. The project also presented a challenge with regards to programming with a minimal mobilisation period and a requirement from the client to gain possession as early as possible to release the pressure on the existing parking facility.

• Construction of a new car parking facility for approximately 100 spaces covering an area of 2,630m2

• Four areas consisting of permeable block-work and asphalt surfacing

• Installation of new car park lighting and controlled entry/ exit system

• Installation of a sustainable drainage system

New Taxiway at St. Mary's Airport, Isle of Scilly

Project Principals and Objectives

The airport required a new taxiway from the runway to the apron alongside the existing terminal building to accommodate additional air traffic. Due to the nature and location of the site at St. Mary’s Airport the design approach was based upon a plastic reinforced grass paving system that relies on the ground conditions being capable of withstanding the design loading profiles from the critical aircraft.

The scheme was awarded on a 40% quality and 60% cost evaluation basis and through this Ryebridge was able to demonstrate a history of successfully delivering numerous infrastructure projects in a challenging airport environment, both on landside and airside.

Principal Operations

• Re-profiling of existing ground levels to suit new taxiway surface levels

• Sub base construction

• Installation of approx. 1,500m2 of Groundtrax Anchored Paving System

• Concrete tie ins to existing runway and apron

• Relocation of existing Airport Ground Lighting

Harwich Port Freight Entrance Works

Ryebridge Construction was awarded the contract to deliver the Port of Harwich Entrance works, secured by competitive tender. Ryebridge has over ten years’ experience working in restrictive operationally constrained environments such as Airports and this experience was invaluable in successfully delivering the project.

The fundamental objective was to ensure that the works were successfully completed with no ongoing operational impact for the client. The existing freight entrance was adjacent to the new entrance and it was business critical that the main entrance and surrounding areas were kept operational.

• Installation of service ducting

• Demolition of existing control facility

• Construction of insitu RC foundation and base slab for new facility

• Re-configuration of existing Port entrance involving kerbing, drainage, asphalt surfacing, road marking and security fencing

• Installation of new control facility canopy building

• Relocation of all IT and electrical control systems

London Luton Airport £9.4m Foxtrot taxiway and de-icing facility

The new taxiway is 520m long, and required 6,000m3 of concrete and 110,000 hours to complete. 9km of electric cables connect the 150 LED lights on the new taxiway.

Taxiway Foxtrot also includes one of the largest remote de-icing facilities in Europe.  The facility can de-ice up to seven planes at once and incorporates 600m of drainage to ensure that all de-icing liquid is captured and disposed of safely. This will help the airport to maintain on-time departures during exceptionally cold weather. 

4,000m3 of earth was re-used during the construction phase and the taxiway has been designed to capture de-icing fluids for recycling.

Neil Thompson, Operations Director at LLA said: “This new taxiway will enable us to efficiently manage the ever-increasing number of aircraft that use the airport. The de-icing facility will also help us to and our airline partners to deliver punctual departures year round, whatever the weather.” 

The project was recognised by both RoSPA and Green Apple.

Project Works and Key Quantities

• Establishment of site boundary to land side site Excavation and remediation of historic landfill

• 6,500m2 Dynamic compaction and stabilization

• 20,000m3 Bulk excavation

• 15,000m3 New drainage system, including 1,750m3 attenuation tank New AGL pit and duct system Supply and installation of new jet blast fence

• 180m Supply and installation of new high mast lights including foundations

• 5No Type 1 – 11,000m3 Supply and lay lean mix concrete

• 3,000m3 Supply and lay PQ concrete

• 5,450m3 Reinforced PAV 2 Concrete

• 2,450m3 Pavement design and tie into existing taxiways – 3 locations – 3 bell mouths within restricted working hours and operational restrictions Installation of new AGL’s

• Man Hours Worked – 97,600hrs

• Incidents – 0 Cable Strikes – 0

Completed on time and under budget.

London Luton Airport £2.4 m mid-term car park redevelopment

Project Principals and Objectives

The client needed to enhance the bus route making it more accessible, introduce new stops and increase the number of parking spaces available in the mid-term car park.

In August 2017 Ryebridge was appointed to design and build a circulatory bus route to the MTCP to enable the removal of the current bus spinal lane that acted as the bus drop-off and pick-up route along with passenger vehicle access to create additional parking spaces, segregate pedestrians and interface with pick-up/drop-off buses and passenger vehicles.

Key Quantities Involved

• 4500m2 asphalt

• 2500T Type 1

• 1000m2 MMA Pedestrian Walkway

• 8No new bus stops – fabricated and installed

• 16No new drop-off/pick-up islands

• 450m pedestrian visirail fencing

• 14No new lamp columns

• 650m new ducting for supplies

• 150No new signs and posts

• 2400m new kerbs

£3.5m Temporary Drop-Off Zone and Overbridge

Project Principals and Objectives

In February 2018 Ryebridge was appointed to construct a temporary drop off zone, including a road over bridge structure to facilitate free passenger movement from drop off to terminal.

All works were required for completion no later than 30th May 2018 with the handover of the Mass Passenger Transit (MPT) site on the 1st May.

London Luton Airport required the design and build of an enabling works package consisting of:

• Temporary drop off zone

• Relocated barrier controls

• New perimeter road and supporting road over bridge structures

• Plan and fully implement an enablement strategy for a new Multi-Storey Car Park allowing the existing DOZ to be closed and the site cleared for the construction of the proposed Mass Passenger Transit (MPT) system

• Removal and storage of high mast lights ready for reinstatement at a later date

• From April 2018 the contractor was to permit access onto the Multi-Storey Car Park (SCP) 2 site for 6no test piles to be installed and tested by the MSCP2 contractor.

During the works there was also the requirement that deliveries were not permitted during the Airport’s Peak Operating Period. The Peak Operating Period was between 04:00 and 08:00 daily.

For more information click on the image below.

£7m Signature Flight Support hangar demolition, new aircraft stands, groundworks for new flight services building

Project Works and Key Quantities

• Demolition of 4No Hangars and Buildings including asbestos removal – 9000m2 total

• Establishment of airside/landside compliant fencing

• Waste management and disposal of contaminated ground – H62 demise

• Site clearance and formation preparation

• Excavation and disposal – 6500m3

• Diversion of key services including HV main and installation of new sub-station

• New drainage including interceptors – 5km

• Installation of acoustic fencing inclusive of foundations – 125m 4m high

• Installation of high mast lighting – 8No

• Recycling and crushing to re-use broken out pavements including certification – 3000m3 (passed on to Client as a saving)

• New aircraft pavements – 14000m2 PQ

• Concrete – 6000m3

• Supply, lay and compaction Type 1 – 5400m3

• New AGL installation including new pit and duct network

• Foundations and substructure for new FBO – 3200m2

• Block paving – 2800m2

• Asphalt – 4200m2

• Kerbing – 2500m

Project Principals and Objectives

The project was the demolition of 4No existing Hangars over several phases, construction of a new aircraft apron and cargo compound, groundworks and external works to the new FBO for Signature Flight Services at their existing location at London Luton Airport.

The key objective was to minimize disruption to their existing flight services and London Luton Airport.

For more information click on the image below.

Pre enabling works for the new DART

In August 2017 Ryebridge were contracted to clear the route for the new DART (Direct Airport Rail Transfer) contractor.

The project was predominantly airside and includes perimeter track diversion, de-icing tank relocation, a new snow fleet area, fuel tank relocation, bus parking, airside fence realignment, taxiway realignment, service clearance.

This project is due to be completed by the end of 2017.

£8.2m Hotel Taxiway, Stand 16 and South Stands

Project Works and Key Quantities

• Excavation

• 18500m3 Material recycled and re-used within the works

• 4500m3 Supply and compaction of Type 1

• 12500m3 Cement Bound Granular Material

• 15,700T Foam Base

• 4800T Asphalt Surfacing

• 19500m2 Asphalt reinforcement grid

• 14200m2 PQ Concrete

• 2200m3 Drainage

• 4000m Attenuation Tanks

• 1750m3 AGL Pit and Ducting System

• 7000m and 104 Pits Complete on time and under budget

Complete on time and under budget

Project Principals and Objectives

The project was to construct a new taxiway in order to enable growth in passenger numbers and flights using the airport. In addition, to extend an existing aircraft stand at either end to accommodate 2 additional aircraft. The third area of works was to reconfigure an existing executive aircraft stands to accommodate additional aircraft and new roadway for aircraft maintenance vehicles and plant.

For more information click on the image below.

£80M Tottenham Hotspur Football Club

Project Details

Original contract Site clearance and removal of hazardous material. Principal contractor Management Subcontractors. Bulk dig and hazardous material removal Sheet piling Concrete piles Pile caps Service diversion Infrastructure drainage design and construction Demolition

Project Principals and Objectives

In July 2014 Ryebridge was originally contracted by THFC to undertake a 12 week project valued at £500k with a brief to reduce the existing level of the new stadium site by 1m. By June 2016 the level of Ryebridge’s involvement in the overall project had increased to in excess of £12m as Ryebridge was appointed Principal Contractor.

For more information click on the image below.