The brief

The Central 1 (C1) section of HS2 is being delivered by the Align JV (Bouygues Travaux Publics, Sir Robert McAlpine and Volker Fitzpatrick) and includes a 3.4km viaduct across the Colne Valley. Once complete it will be the longest railway bridge in the UK.

A project of this scale, with all the demands of high-speed rail, presented unique challenges and needed bespoke solutions. Align contacted Keyline’s National Accounts team, requesting

options to carry HV and LV cables, with a complex drainage detail for part of the viaduct. National Account Manager Mike Rees responded to the enquiry, recognising the opportunity to add value with Keyline’s Technical Team.

Keyline was already part of the HS2 supply chain, and had developed a good relationship with the procurement and logistics team of Align. Mike Rees and the Technical Team at Keyline were well-positioned to offer their expertise and assist with a solution. Align provided drawings of the design, and the team held a series of meetings with designers to fully understand their requirements. 

Once given a brief and specification, the Technical Team started to investigate potential solutions and source the market for suitable products.

The challenge

It quickly became clear that no existing solution could be found; the complex details of the design meant that no straightforward “off-the-shelf” product could be made to fit, and a bespoke item was required. 

Keyline started the process of developing a product and design for the viaduct. Project requirements and design complexities were considered alongside budget and logistical constraints.

The Technical Team – which includes in-house civil engineers – explored several options, including a GRP solution, composite concrete, cast in-situ, and precast concrete. The team balanced design requirements with commercial constraints; GRP, for example, wasn’t viable as a solution because it required the development of bespoke tooling and adjusting the manufacturing method, which was not commercially viable for only one product. 

In a project with lots of nuances and potential for design changes, the solution needed to be flexible. Production had to be smooth, meeting strict deadlines and making installation as straightforward as possible. Keyline could support and facilitate the process from start to finish, ensuring a solution was found and implemented effectively. 

The solution

Pre-cast concrete fit the criteria; it was the most flexible solution, allowing Align to tweak and update the design and still meet the deadline for installation on site. It was also the most cost-effective.

Collaboration with manufacturers

Once Keyline had identified this, several manufacturers were engaged and given the outline of what was required. Anderton Concrete, the Rail and Infrastructure specialists of Ibstock was chosen – they were able to respond best to the brief, and had the correct technical capabilities and capacity required. Ibstock - Anderton Concrete was also already on the HS2 framework, which would make material and supplier approvals smoother, and had an existing relationship with Keyline.

Collaboration with Ibstock - Anderton Concrete began by refining the project wants and needs, and taking into account the requirements of the package managers and Align. Development was a thorough process. Keyline facilitated sample products being made, test fits on site and used trial outcomes to further develop the product. Following extensive testing, when the results were obtained and the design approved, the product went into full production.

Serena Solanki, National Engineering Manager at Keyline Civils Specialist, emphasised the importance of a collaborative working relationship in finding bespoke solutions: “It can sometimes be difficult communicating your needs and wants to a manufacturer. Because of the experience Keyline has, with logistics, the challenges of installing products on site, and how they are manufactured, we create a collaborative environment. We speak the languages of both our customers and the manufacturers, finding a solution that works for everyone.”  

Adjusting palletisation: making installation smoother

Keyline’s understanding of logistical requirements, and the challenges faced by both contractor and manufacturer, proved invaluable. Helping to coordinate the entire process allowed them to support both; Keyline supported from a buildability point of view, and helped Ibstock - Anderton Concrete understand the logistical requirements. 

Keyline facilitated changing how the products were palletised, with three different components per pallet instead of the standard single component. This would help speed up the installation process. The site team didn’t have to break down various pallets to find the components required and had a clear understanding of how many pallets would be needed per shift, making ordering straightforward. This change helped the installation program maintain a continual process.

Keyline assisted Ibstock - Anderton Concrete with the adjustment – the manufacturer had to change how they were storing and producing materials, adapting their production lines so that they could palletise thousands of units this way. 

From the first approach of Align to the installation on site, Keyline was a constant source of support. From finding a bespoke solution to a challenging design problem, to working with Ibstock - Anderton Concrete to develop the product and make installation smooth; Keyline and the Technical Team added real value to the project, reinforcing the importance of collaboration for our industry. 

To find out how our Technical Team can add value to your project, contact us today at keylinetechnical@keyline.co.uk.